Smokaroma BB 71, BB 73, BC 71, BC 73, BCD 71, BCD 73 Barbequer Service Manual

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Smokaroma Barbequer BB 71, BB 73, BC 71, BC 73, BCD 71, BCD 73 Service Manual | Manualzz

Description of Models

This service manual is written for models

BB,

BC, and qeD series. There are two models for each series. r example, in the BB series, there are models BB71 d BB73. The only difference between the two Is the phase. On all models, the model designated '71" is a single phase unit and the model designated ,3" is a 3 phase unit.

All models can be changed in the field to either 20S

VAC or 240 VAC. If the voltage is not specified when ordered, the unit will be wired for 208 VAC at the fac­ tory. It may be changed to 240 VAC by disconnecting the top element. A single phase unit may be changed to

3 phase with a change of cord and relay. This may be ordered as a modiflcatlon kit (see page 24).

The BB unit is the smallest model. It is easily identifi­ able as having only four (4) clamp down knobs on top.

It has an inside pot diameter of 13 5IS". The BC is an intermediate size pot and has six (6) clamp down knobs on top. It has an inside pot diameter of 14 SIS" 1.0.

The BCD is the largest size. The BCD model is basi­ cally a double BC or two

BC units put together in a single cabinet. Although there is a single power source on the BCD model, the controls mounted behind the pres­ sure pot operate that particular pot. This means that each set of controls for each pot operates Independently of each other. This gives fleXIbility in loading and tim­ ing. It also means you won't be out of the barbecue business if one side happens to malfunction. The other side still should work

Independently of that side.

As far as service and repairs are concerned, all the mod­ els have the same circuitry, and operate the same.

Therefore, the service will be substantially the same on all three models. The only difference in the models are

Size and wattage. These difference will be pointed out in the service manual.

BB BC BCD

Description of

Operation

The Smokaroma barbequer combines the modem sci­ entific method of pressure baking with pressure smok­ ing to get that "old-fashion- hickory smoke flavor. It does this economically, automatically. and in a fraction of the time to prepare barbeQue by ordinary methods.

In operation as a barbequer, a small amount of hickory is placed in the smoke generator cup. Meats or foods to be cooked are prepared according to the recipes and then either placed in racks which stack one on top of the other, food basket. or hung from spits on the meat rack. The capacity of each rack

or

food basket shelf is approximately Sibs. of meat. The meat rack spits will accommodate approximately

30 to 45 Ibs. of meat. Af­ ter the cooker is loaded with the desired amounts of food to be cooked, the lid Is placed thereon such that the two "L· shaped slots are aligned with their respec­ tive clamp bolts and knobs. The two knobs are rotated

...ward in the slots to the upright position. Then the

.J is rotated clockwise until It stops. The remaining

Clamp bolts (2 on the BB and 4 on the BC and BCD) may then be rotated upward In the slots and tightened.

Tighten opposite knobs at the same time until all are snug.

Before heat is applied, the ejector or pressure relief valve should be placed in the closed (horizontal) position . The drain valve should also be closed . It is not necessary or desirable to release the air within the cooker.

The heat is applied when the timer is set.

This causes the unit to build pressure . The wood then chars and creates smoke, which being under pressure, is forced all through the food.

The in i tial pressure begins at 0 psi and builds to 15 psi.

Then the pressure may vary between 10 psi and 15 psi as heat Is automatically applied and removed. The pres­ sure and temperature are automatically regulated. A pressure solenoid valve will release a small amount of steam should the pressure start to build over 15 psi.

The ejector or pressure relief valve is open when the stem is erected in a vertical position and closed when it is in a horizontal position. There is a safety pressure relief valve which will release the pressure if it exceeds

16 to 17 psi.

At the end of the cooking cycle, the pressure will be automatically released. When the pressure gauge in­ dicates zero pressure, the ejector valve should be placed in the vertical (open) position to insure complete exhaust. The cooker may be opened and the cooked food may then be removed.

-1­

SmokaromaPreventive Maintenance

Suggestions

DAILY

1. At the end of each day, completely clean inte­ rior of the Bar-B-Q Boss. Do not fill with water above bottom of smoke generator. You only need to pour 1 quart of water on the bottom.

Add detergent (such as "Dawn" soap). Scour good with a Scotch Brite maroon pad. Drain water and dry thoroughly. It is not necessary to scour a/l the smoke stain off the cooker. It is only necessary to scour grease and burnt crust of food off the walls, bottom and underside of top.

2.

Clean meat rack or food basket in sink.

3. Wipe underside of lid, O-ring, and cooker pot ring with a damp dish cloth to clean of dirt and debris.

WEEKLY

1. After cleaning machine, squeeze soap solution through top port hole until it runs out port hole in cooker.

2. Flush cooker exhaust system by placing 2 quarts of water into cooker. (Add

1/4

cup soap solution. "Dawn" is excellent.) Run up to pres­ sure and allow cooker to "pop off' for 25 min­ utes.

3. Turn off cooker and exhaust pressure. Remove water and dry cooker.

4. Lubricate knobs and bolt threads, underside of knobs, and top of lid where knobs turn.

"CLEANLINESS

MONTHLY

IS

90%

OF

MAINTENANCE"

COPPER FILTER

'CH~ BOY'

PT.

NO. 1790

Figure 1

There is a copper "Chore Boy" filter located Inside the exhaust port. The exhaust port is located on the left inside of the cooker, just to the left of the charring element housing, if looking from the front of the machine. The purpose of this filter Is to pre­ vent food particles from entering your exhaust sys­ tem and clogging the lines. You should not oper­ ate the machine without the filter in place. Change the filter according to No.9 of "Monthly Mainte­ nance Suggestions".

1. Observe pressure cut off point. Green light should "cut off" at 12 psi. If not, see service manual (page 22) for adjustment.

2. Observe pressure exhaust point. Exhaust should occur at between 14 to 15 psI. If not, see service manual (page 22) for adjustment.

3. Observe timer cut off point. Dial should point to "Zero" at

cut

off point. If not, remove dial knob and adjust.

4. Observe gauge to see if it remains in calibra­ tion, especially after abuse (for example, see if the gauge leaks, or if the dial is bent, etc.). If not in calibration, replace the gauge.

5. Tighten any loose nuts, bolts, or screws.

6. If ejector valve leaks, replace it.

1.

Do not tamper with safety valve. If it leaks, re­ place it.

8. Examine units for any broken, missing, or de.

teriorated parts. Replace immediately; do no\..

operate in a defective condition.

9. Change "Chore Boy" filter at least once per month and more often with heavy usage.

-2­

. Figure 2

Controls

&

Functions

6. Green Neon Indicator Ught (Pressure)

Indicates voltage is applied through pressure switch to heating elements. Should go out at 12 psi. Green light will not light in "Cold Smoke" mode.

7. White Neon Indicator Light (Cold Smoke)

Indicates when "Cold Smoke" switch is in the "Cold

Smoke" mode.

8.

Ejector Valve

Provides manual valve for closing to build pres­ sure and opening to relieve pressure.

9.

Safety Valve

Provides valve for relieving pressure should it ex­ ceed 17 psi. Resets at 15 psi.

1.

TImer Switch

Provides timed on-off main switch. All lights should come on when first turned on if thermostat is in

"Bar B-O" position.

2. Red Neon Indicator Light (Power)

Indicates timer switch Is on and power is being ap­ plied to machine.

3.

Thermostat

' ovides automatic "Hold" control. Provides over­ eat prevention control. When set at IIBar S.a· position. thermostat will cut out .

at a bottom tem­ perature of 550 0 F. When this happens. both the temperature neon light (amber) and the green neon light will go off, or if in "Cold Smoke" mode the amber and white light will go off. When the tem­ perature drops below 550 0 automatically cut back on.

F, the thermostat will

4. Amber Neon Indicator Light (Temperature)

Indicated voltage is being applied through thermo­ stat to heating elements.

5. "Cold Smoke" Switch

Provides "Cold Smoke"- "Hot Smoke" mode. In the

"Qtr or down position, the unit is in the "Cold

Smoke· mode; only the Charring Element will heat.

The white neon light will come on (with amber and red) when the timer is set to "On" and the thermo­ stat is set to Bar-S-O.

In the "On" or up position, the unit is in the "Hot

Smoke" mode. The main elements will provide

"eat along with the Charring Element. The green jon light will be on (with amber and red) when

->th e timer is set to "On" and the thermostat is set to

Bar-B-O. However, the green light will cycle off when approximately 12 psi is reached and on when pressure drops below 10 psi.

10. Pressure Gauge

Indicates pressure (psi). After initial pressure is built up, it normally operates between 12 .

and

15 psi (indicated by green area).

11.

Drain Pan

Use In cleaning cooker. It Is located beneath the cooker directly beneath the drain valve. Pan catches drippings out of cooker pot when opening drain valve. .

12. Charring Cup

Container which holds wood for charring during the smoking process.

13. Charring Element

Provides heat source of 230 watts at 240 volts for charring wood.

14.

Lid Rack

Used to hold the top lid when not in use. It is lo­ cated on side of cooker cabinet.

15. Muffler

Designed to condense some moisture being re­ leased from the machine and prevent splattering on the wall.

16. Drain Valve and Handle

Provides for cleaning when opened. Should be closed during the cooking operation. Valve is opened when handle is rotated counterclockwise to the down or vertical position.

17. O-Ring

Provides pressure seal when lid is clamped in place.

-3­

·

Controls

&

Functions

Figure 3

18. Power Relay

Provides power to the main elements when en­ ergized by control circuit~ The control circuit consists of timer switch. thermostat and Pres­ sure Switch No.1, all in series with power relay coil. at end of cooking cycle and to control pressure at below 15 psi by exhausting intermittently dur­ ing cooking cycle. The exhaust solenoid Is con­ trolled by the Timer Switch and Pressure Switch

NO.2.

19. Main Elements

PrOVides main source of heat. Each element is rated at 1540 watts

@

240V for the BS and 1650 watts

@

240V for the Be and BCD. Four (4) elements are used

@

208V. The extra element at the lower voltage (208V) produces about the same wattage as three (3) elements at the higher voltage (240V). Three (3) elements are used

@

240V.

21. Terminal Strip (TB-1 thru 5)

Provides junction for connecting wires.

22. Low Side (Left) Pressure Switch (No.1)

Opens control circuit at 12 psi to de-energize

Power Relay thereby removing heat. Closes at

11 psi on pressure drop to energize power relay the reby adding heat.

20. Exhaust Solenoid

Provides valve to exhaust steam automatically

-4­

23. High

Side

(Right)

Pressure Switch

(No.2)

Opens solenoid at approximately 14

1/2

psi to control pressure at below 15 psi. Closes at ap­ proximately 13

1/2

psi on pressure drop.

Quick Check for

Functions

&

Controls

The following is a method of performing quick checks on the 8ar:-B-O Boss to see if it is functioning rrectly. It ma.lnly consists of visual checks and checks by touch . It is divided into three parts: "Function checks for Indicator Lights ...", "Function checks for Power Relay ..•", and "Function checks for leaks ..."

Be sure all checks are made before going to another part.

1. Function checks for Indicator Lights, Time Switch, Thermostat, Pressure Switch and Solenoid.

A. Action:

1. Plug machine into outlet of proper voltage. (See nameplate).

2. Turn thermostat knob to the "Sar-S-O" position.

3. Rotate timer switch to 1 hour and slowly back to the "0" position.

B. Checks The following should happen: All indicator lights (except cold smoke light when cold smoke switch is in the up position) should light and then go off when the pointer on the time switch reaches "0" time.

C. Possible Troubles -

If these things do not happen, it may indicate one or more of the following troubles: .

SYMPTOMS a . No indicator lights come on.

POSSIBLE TROUBLES

1. Assuming correct · voltage is available at the outlet, defective wiring in power cord.

TO REPAIR SEE:

"I. Won't Heat, 9, Detailed

Trouble Shooting Charf', page

8 and "Wiring Diagram", pages 31 , 32, and 33.

2. Defective wiring in control box.

3. Defective timer switch

"I. Won't Heat, C, Detailed

Trouble Shooting Chart", page 8 and "Wiring

Diagram", pages 31,32 and 33.

"I. Won't Heat, D, Detailed

Trouble Shooting Chart", page

8 and "How

Replace Timer Switch", page 20.

Exploded Parts Sheet, page 30. 4. Defective lights. b. Power light comes on but Amber (Temperature) and Green (PresslJe) lights do not come on.

1. Defective wiring.

Wiring diagram pages 31, 32, and 33.

2. Defective thermostat. "I. Won't Heat, E, Detailed

Trouble Shooting Chart", page 8.

3. Defective lights

4. Thermostat must be turned to

8ar-8-Q position.

-5­

Exploded Parts Sheet, page 30.

Quick Check for Functions

&

Controls

c. Power and temperature lights (Red and Amber) comes on but Green pressure) light does not come on.

1. Defective wiring.

2. Defective Pressure Switch.

Wiring diagram. pa.ges

31 t

32 and

33.

"I. Won't Heat Detailed

Trouble Shooting Chart", page

8.

3. Defective Lights. Exploded Parts Sheet, page 30.

4. Defective Cold Smoke Switch.

D.

Action - Press "Cold Smoke" down to Cold Smoke position. Repeat above A,

B,

and C.

E. Assuming that all controls function correctly when checked above, a further check should be made as follows:

II.

Function checks for Power Relay, Charring Element, and Main Elements:

A. Actions and Checks: Caution: These checks should only be done when cooker is cold or from a cold start.

1.

Rotate thermostat to the

"BAR-B-Q" position and then rotate timer switch to

"2" hours on the dial. All lights should light and solenoid should energize.

2. Immediately remove top and briefly touch the charring rod. It should start to get hot to the touch in a very short time.

3. Put hands on lower side of cooker to see if it becomes warm when the cooker is cold, it may take several minutes before the side becomes warm to the touch.

B.

Possible Trouble - If these things do not happen it may indicate one or more of the following problems. .

SYMPTOMS e. Charring Element does not become warm.

POSSIBLE TROUBLES

1. Defective wiring.

TO REPAIR SEE:

For all troubles listed here, see

"IV . . Won't Create Smoke,

. Detailed Trouble Shooting

Chart'", page

13.

2. Defective Thermostat. f. Side of cooker does not warm.

3. Defective Charring Element

1. Defective wiring. For all troubles listed here, see

"I. Won't Heat, Detailed Trouble

Shooting Chart", page 8.

2. Defective Power Relay.

3. Defective Main Elements.

4. Cold Smoke Switch must be in "UP" position and green light is "on".

(Note: This unit has four separate elements. Therefore it's rare that all elements will burn out at once unless an over voltage has been applied. Most likely the wires from the power relay are defective.

·6­

F. Assuming that all controls or parts are functioning correctly to this point, make the following test:

III. Pressure checks for leaks, check for solenoid functioning, calibration checks for pressure switch and time switch and addition check for maIn element.

'\ I

A. Action:

1. Remove the meat rack assembly or food basket, and charring cup.

2. Put 1 quart of water on the bottom.

3. Rotate thermostat to the "Bar-B-Q" pOSition and then rotate time switch dial to "2" hours.

(Note time on your watch when time switch was set to "2" hours.)

4. Place top on and clamp down with ejector valve in the closed position.

B.

Checks - When this is done the following should happen:

1. Pressure should build.

2. The timer switch should move one mark clockwise after 5 minutes.

3. The green light (Pressure) should go out when the pointer of gauge is at 12 psi when pres sure is rising.

4. The solenoid should exhaust when the pOinter of the gauge is between 14 and 15 psi when pressure is rising. a.

C. Possible Troubles - If these things do not happen, it may indicate one or more of the following problems:

SYMPTOMS

Pressure does not start to rise at all after 15 minutes.

POSSIBLE TROUBLES

1.

Leak

2. Defective Gauge

TO REPAIR SEE: .

"III. Heats But Won't Build

Pressure, Detailed Trouble

Shooting Chart", page 12.

3. Defective Ejector, release, or safety valve

4. Defective Drain Valve b. Pressure starts to rise but does not get over

5 psi.

1.

See

A 1, A2, and

A3 above.

2. One or more Main Elements is defective.

"". D.

Heats Only Warm,

Detailed Trouble Shooting

Chart", page 11. c. Green light will not go out at 12 psi. d. Pressure will not release at

141/2

psi.

1. Pressure setting is too high

1. Pressure Switch setting is too high or low.

2. Defective solenoid

3. Pressure line stopped up.

"How to Adjust Pressure

Switch", page 22.

"How to Adjust Pressure

Switch", page

22.

"VII. Won't Exhaust, Detailed

Trouble Shooting Chart", page 16.

-7­

Detailed Trouble Shooting Chart

FOREWORD TO THE "DETAILED TROUBLE SHOOTING CHART LIST"

The Detailed Trouble Shooting Chart list the "Trouble", what to "Check or Adjusf and what further

YOlO need to do to fix it under "For Information See". We tried to list the "Trouble" just as the customer waul experience or say it. The most prevalent trouble, "Won't Hear is listed first. To repair, find the description which is mostly closely associated with the problem and proceed step by step down the "Check or Adjust" list. When the problem is isolated to a part, see the reference listed under "For Further Information See". If this solves the problem, you may then test the unit according to the "Quick Check" to make sure everything is functioning correctly. If it is, congratulations, if it is not, proceed to the next step.

Generally the procedure is written for low voltage (208 to 240V AC) and Single phase. Since all control circuits (208 to 240V AC, single phase) are the same regardless of the voltage or phase, the trouble shoot­ ing will be the same for it. Where the procedure differs it will be marked clearly with a phrase "For 3­

Phase".

Detailed Trouble Shooting Chart

TROUBLE CHECK OR ADJUST FOR FURTHER

INFORMATION SEE:

1.

WON'T HEAT

A. VOLTAGE - (Thermostat should be rotated to the "SAR-S-O" position). Voltage at outlet should be same as voltage specified on name plate

±

5%. If not, have electrician to correct.

B. Make sure unit is disconnected from outlet.

Remove back cover, check all wire connections for loose or burnt connections. Plug into outlet and measure voltage across terminal R·1 and

R-2 of power relay. Voltage should be the same as that specified on name plate

±

5%. If not, check handle cap (plug) to see if it is wired right.

(Green is ground.)

For 3 phase: Check voltages across terminals

R-1 and R-2, across R-1 and R-3, and across

R-2 and R-3. Voltage should be the same as that specified by the name plate

±

5%.

C. Check voltage R-1 and TB-S. It should show

208 to 240 VAC

±

5%. If not, replace white wire from R-2 to TB-5.

D.

TIMER SWITCH - Check time switch as follows:

1. Turn timer switch to "1" hour position.

Name plate on back of of cover of 8ar-8-Q Boss.

"How to Remove Back

Panel", page 20 and

"Wiring Diagram" on pages 30, 31, and 32.

"Wiring Diagram· on pages 30, 31, and 32.

2. Connect voltmeter across TB-1 and TB-5 on terminal strip. Voltmeter should read 208 to

240 VAC

±

5%. If it does, proceed to

"En.

. "Wiring Diagram" on pages 30, 31, and 32.

3. If it does not, check wiring up to this point by removing black wire to timer switch, from the timer switch terminal. Connect voltmeter across the end of the black wire and at relay

R-2 terminal. Voltmeter should read 208 to

240 VAC

±

5%. If It does not, replace black wire.

-8­

"Wiring Diagram" on pages 30, 31, and 32.

4. Turn timer switch to the "On" position and measure the voltage from the timer switch terminal where the orange wire is connected and TB-S. The voltmeter should read 208 to

240 VAC

±

5%. If it does not, replace the timer switch. If it does, connect voltmeter across

TB-1 and TB-5 on terminal strip. Voltmeter should read 208 to 240 V AC

±

5%. If it does not, replace orange wire. If it does, proceed to "E" below.

E. THERMOSTAT - The thermostat should be in the "BAR-B-a- position. Check the voltage between TB-2 and TB-S. The meter should show

208 to 240 VAC

±

5%. If it does not, check the voltage between the thermostat terminal where the purple wire connects and TB-5. Voltmeter should read 208 to 240 VAC

±

5%.

If it does not, replace the purple wire. If 208 to 240 VAC

±

5% appears, then check and see if It appears between the thermostat terminal on which the black and white striped wire is connected and TB-S. If it does not, replace the thermostat. If 208 to 240

VAC

±

5% appears, then proceed to "P.

"How to Replace Timer

Switch", on page 20.

"How to Replace

Thermostat", page 21.

See "Wiring Diagram", pages 30, 31 and 32.

F. PRESSURE SWITCH NO.1 - Check voltage with voltmeter between Pressure Switch No.1 terminal (left pressure switch) on which the green wire appears and TB-5. Voltmeter should read 208 to 240 VAC

±

5%. If it does not, replace the green wire. If it does, check the voltage between the Pressure Switch No.1 terminal on which the blue wire appears and TB-5; 208 to 240

VAC

±

5% showd appear. If it does not, adjust the pressure switch. If pressure will not adjust, replace pressure switch. If the voltmeter does read 208 to 240 VAC

±

5% proceed to

"Gil below and check.

'Wiring Diagram- on pages 30, 31 and 32.

"How to Adjust Pressure

Switch", page 22.

"How to Replace Pressure

Switch, page 22.

G. POWER RELAY - Check the voltage with a volt­ meter between terminals R-4 and R-5 on the power relay coil. Voltmeter should read 208 to

240 VAC

±

5%. If it does, and the relay is not energized, replace the relay. If the voltmeter does not read 208 to 240 VAC

±

S% check the voltage between R-4 and TB-5. Voltmeter should read 208 to 240 VAC

±

5%. If it does not, replace the blue wire to the coil. If it does read 208 to

240 VAC

±

5%, replace the white wire from the coil to TB-S. If the relay is energized and elements do not heat, proceed to "H- and check.

"Wiring Diagram- on pages 30, 31 and 32, and

How to Replace Power

RelaY'. page 23.

H. MAIN ELEMENTS - Remove bottom control panel cover to expose the element ends. There are four (4) elements per cooking unit. Three (3) are used for 240/415 volts operation and four (4) are used for 208-220/380 volts operation. Check the voltage between R-6 and R-7 of the power relay with the relay energized. The voltmeter should read 208 to 240 VAC

±

5%.

-9­

"How to Remove Back

Panel and Bottom Control

Panel Cover". page 20.

Wiring Diagram, pages

30,31 and 32.

Detailed Trouble Shooting Chart

For 3 Phase: With the relay energized, check the voltage between R-6 and R-7, between R-6 and R-a and between R-7 and R-B. Voltage should be the same, in each case, as that specified by the name plate

±

5%. .

Single Phase Cont.: Check the voltage at the element terminals where the leads are connected.

The voltmeter should read 20B to 240 VAC

±

5%.

If it does not, check continuity of the lead wires by connecting one (1) voltmeter lead to R-6 and one (1) voltmeter lead to the element terminal on the left side.

Voltmeter should read 208 to 240 VAC

±

5%. If it does not, replace the lead wire on the left side.

Reverse this process by checking the voltage between terminal R-7 on the power relay and the element terminal on the right side of the elements. The voltmeter should read line voltage

±

5%.

If it does not, replace the lead on the right side.

"How to Replace Heating

Element", page 29.

If the voltmeter reads line voltages across the terminal of the elements and anyone does not heat, remove all connections on the elements and check the resistance with ohmmeter of each element. The resistance should read 35 ohms

±

5% for the BC and BCD and 37

±

5% ohms for the

BB.

If the ohmmeter indicates differently than these values, replace the element or elements.

For 3 Phase: Check the voltage at the element terminals where each of the three leads are connected. That is, check between lead one (1) and lead two (2), lead one (1 and lead three (3), and ' lead two (2) and three (3). In each case, the voltmeter should read line voltage

±

5%. If it does not, check continuity of the lead wire by connecting one voltmeter lead to R-6 and any of the other two corresponding lead terminal at the element. For example, if your voltmeter lead is on R-6 then the other lead should be on the lead terminal end at the element of lead two (2).

The voltmeter should read line voltage. If it does not, re­ place lead two (2). Repeat this process for R-7 checking the voltage at the end of lead 3 at the element terminal.

Also for R-8, checking the voltage at the end of lead one (1) at the element terminal. You may also check con­ tinuity of the lead wires with an ohmmeter. Be sure the unit is unplugged and voltage is removed. Check the continuity by measuring between R-6 and the end of the lead in at the element terminal. If it does not have cont.inuity, replace the lead. Repeat this process for R-7 and R-8.

It lhe

voPbrrem reads line voltage across the terminals of any of the elementS and any one element does not heat, re­ move all connections on the element and check the resis­ tance with the ohmmeter of each element. The resistance should read 35 ohms

±

5% for the Be and the BCD, and

37

±

5% ohms for the

BB.

If the ohmmeter indicates differ­ ently then these values, replace the element or elements.

-10­

De

tailed Trouble Shooting Chart

C H ECK OR ADJ U S T FOR FURTHE R

INF ORMATI ON SEE: n.

HEATS ONLY

WARM AND

PRESSURE

BUILDS UP

EXCEEDINGLY

SLOW

A. VOLTAGE - Check line voltage and be sure that the voltage [s same as specified on nameplate

±

5%. If it

Is, check and see if

208 to 240 VAC

±

5% Is applied to the L 1 and L2 wires in power coret Green wire should be grounded. Sometimes with a three wire power cord, a lower voltage is applied to the cooker through error. If this Is the

case, correct

plug or receptacle such that the correct voltage is applied, to

L 1 and

L2 wires in power cord.

For 3 Phase: Une voltage should appear between l1 and L2, L 1 and l3. and L2 and

La.

Wiring Diagram, pages

30, 31 and 32.

B. Check amperage with an "Amp ro b e· type meter by encircling one lead to main elements. It should read not less than 20 amperes (See Wiring Diagram page 30 for actual current on l1 and L2). If it reads

.Iess than 20 amperes, recheck • A" above and then proceed to "C" below.

For 3 phase: this c urrent r eading shou ld not be les s than 5 amperes but no t more t han

11 ampheres. (See WIring Diagrams, pa ge s

31 a nd 32) for a ct ual current on l1, L2, and L3.

Wiring Diagram. pages

30.

31 and

32.

C. MAIN EL EME NT S With the ti m e r switc h

·On" and the ther mostat ro ta t ed to "Ba r -B-a" position, check voltage at terminals of element.

It should be the same as the 208 to 240 VAC

±

5%. If It Isn't, check through -I. Wontt Heat,

Detailed T r ouble Shooting Chart" then correct defectiv e parts . If the 208 to 240 V AC

±

5 % app ears across termi nals of main elements proceed to "H· "I. Won't Heat, Detailed Trouble

Shooting Chart".

-11­

"H ow to Replace Main

Element", page 29.

Detailed Trouble Shooting Chart

TROUBLE

CHECK OR ADJUST FOR FURTHER

INFORMATION SEE:

m.

HEATS BUT

WON'T BUrLD

PRESSURE

A. GAUGE - Check for leaks around gauge connections. If loose. tighten. Check gauge to see if pointer is unobstructed. If defective, replace gauge.

B.

EJECTOR VALVE - When stem is down. ejector valve should be closed and pressure tight. If the ejector valve leaks. replace.

C. S A F ETY VALV E S afe ty v a lve should funct io n at 17 ± 1 psI. It will the n reset I ts elf , at a pp ro xi­ m ately 15 pst. I f the safety te n ds to leak slightly, som e tim e s

It can be stopped by slight pressure with your finger. If it continues to leak, replace.

D. SEAL - Check O-ring for c rac k s or b reak s .

Ch e c k O-ri n g and the s urface w here

It seats on the pot ring. Both sho u ld be f r ee of fo r eign m atter, suc h as . hickory s h avings, pre p mi x or sau ce . Th e pot ri n g s h o u l d also be fr e e of n i c k s an d scars.

E. PL UM B ING - Check aJl connections and pipe fittin g In panel for leaks. Check manifold co n nec tions on cooker body, and ar o u n d d rain val ve for leaks (preferably with air pr ess u r e and us i n g so ap s uds) . Tighten an y loose fittin g s .

Rep lace d rain v a lv e if it leaks.

F. V O L TAG E A T SOLENOID - Ch eck vo ltage acro ss t erm i nal w i th bl a c k w i re on right pressur e s w i t c h (No.2) and T 85, 20 8 to 240 V AC

±

5 % shou ld a ppear . If it does and solenoid will not clo s e, r e plac e s olenoid . I f 208 to 240 VAC

±

5% does not ap p ea r a t the s e t erminals with power on, check "A through -0- of "I. Won't Hea t ,

Detailed Trouble Shooting Chart". If this checks out, then, check voltage between terminal with black wire on right pressure switch (No.2) and

TB-5, 208 to 240 VAC

±

5% should appear.

If not, check adjustment of right Pressure Switch

(No.2). If pressure switch will not adjust. replace pressure switch.

-12·

"H o w

to

R e p lace

S o le n old-, page 25

.

"H o w to Ad j ust

Pres s u r e Switch-. page 22.

"How to

Replace

Pressure Switch-, page 22.

De

t

ailed Trouble Shooting Chart

"P 'l

OUBLE

IV. WON ' T

CREATE

SMOKE

CHE CK OR ADJUST

FOR FURTHER

INFORMATION SEE:

A.

V OLTAGE -

With time switch set at "1· hour an d thermostat at "B ar -B-Q" position, c h eck v olt­ age across TB2 and TB-S. LIne voltage sh ould appear . ch ecked

If

not, voltage should be as spec if ied In

"A"

through

"E·

under

III.

Won' t Hear trouble.

B . CHARRING E LE MEN T -

If 208 to 240 VAC

±

5% appea rs acr oss T8-2 and T8-5, t he charring element should he at. If it does not, check for loose terminals. If none are found. replace charring element. AHemate: Check the r esi stance of the charring element with an ohmmeter. It should read 250 ohms

±

10%.

If it does not, replace the charring element.

"How to Replace

Charring Element", page 21.

'rROUBLE

V.OV

E RHEATS

CHE CK OR ADJUST

FOR FURTHER

INFORMATION SEE:

A. Check for leaks.

If

cooker is leaking, It cannot get up to cutoff pressure (12 psi for left pressure switch No.1) to open solenoid and remove heat, and cooker will overheat.

B. LEFT

PRESSURE

SWITCH (1) - Pressure switch should cut off at 12 psI. If It does not, adjust pressure switch to cut off at this pressure. If pressure switch will not adjust, replace.

C. RIGHT

PRESSURE

SWITCH (2) - Pressure switch should open.solenold at 14

1/2

psi and release pressure to approximately 13

112

psi.

If it does not, adjust pressure to open at

141/2 psi. If pressure switch will not adjust, replace.

D.

T HERM O ST AT -

The thermo stat is d e sig ned to p revent overheating, and p oss i ble damage to unit. It Is designed to cut off at a temperature of 550 0 F at point on w h ic h the thermostat bulb is mounted. Rotate thermostat knob slowly toward

"oW.

Thermostat should click off . somewhere between "hold" and "orr posItion at approximately the 2: 0 0 o' clock position .

-13­

"How to Adjust Pressure

Switch", page 22.

"How to Replace Pressure

Switch·, page 22.

"How to Adjust Pressure

Switch", page 22 .

"How to Replace Pressure

Switch", page 22.

"How to R e place

Therm ostar , page 21.

Detailed Trouble Shooting Chart

TROUBLE

CHECK OR ADJUST FOR FURTHER

INFORMATION SEE:

J

E.

MAIN

ELEMENTS - Check element connection Rewire Connections configuration to see if they are wired for the

~ring

Dlagram-. right voltage. (See bottom of wiring pages 31, 32 and 33. diagram.) For low voltage (208 to 220/380 volts) operation. four (4) elements are used. For high voltage operation (240/415 volts). three (3) elements are used. If four (4) elements are used on high voltage operation, the unit will overheat. Rewire connections. if incorrect.

For Single Phase: Elements are connected in parallel.

For 3 Phase: Elements are connected either in a -Delta- or -vlye- configuration.

F. POWER RELAY - Power relay should be normally -How to Replace Power

. open when no volt age is ap pli ed . You should be

RelaY', page 23. able to move the co n tacto r from the nonn ally closed position with your fin ge rs (make sure power Is removed before trying this). If the contacts are welded in the normally closed position. relay should be replaced. If contact points are badly pitted. replace power relay. .

TROUBLE

VI. PRESSURE

BUILDS UP

HIGH

CHECK OR ADJUST

A. CHECKING PRESSURE LINES A ND CONN ECTORS

1. Check large exhaust port hole, and adapt er located inside cooker above and to the left of the charring element cavity. Remove back panel.

Be

sure hose and adapter are not stopped up by disconnecting hose f rom solenoid and blowing through hose. If there is any obstruction, replace ho se andlor adapter.

2. Remove Muffler and blow .

through it to be sure it is not stopped up. Clean to remo ve an y o bst ruction.

3. Check pressure switch port hole located on back

-14­

FOR FURTHER

INFORMATION SEE:

Detailed Trouble Shooting

C hart of charring e leme nt housing. Be sure it is not sto pped u p by d is co nnecting hose from pressure s witches manifold and b lowing th rough hose . If there is any obstruction, replace h ose and/or adapter .

B. LEFT PR ESS URE SWITCH (1) Observe pressure Indicated on gauge at which pressure

Indicator light (green) c uts off . Thi s po i nt s hould be at 12 pSi. If not, adjust pressure switch to open at this point I f pressure swit ch w ill not adjust, replace .

-How to A djust Pre s sure

Switch-, page 22 .

"How to Replace

Pressure Switch-, page 22.

C. RIGHT PRESSURE SWITCH (2) Pressure switch should open solenoid at

14112

psI and release pressure to approximately

131/2

psI.

If it does not, adjust pressure switch to op en at

14112

psI. If pressure switch will n ot adjust, r eplace.

-How to Adjust

Pressure Swltch-, page 22.

" How to Replace

P ressure Switch-, p age 22 .

D. POWER RELAY Power Relay should be normally open when no voltage Is applied. You should be able t o m o ve the contactor fro m the normally closed position with your f i ngers ( make sure powe r cord Is removed before t ry ing this).

If the c ontacts are weld ed in the normally c losed position , replace r e lay . If co nt act points are badly pi tt ed, replace po wer relay .

"How to Replace Power

R e l ay"

I page 23

.

TROUB L E CHECK O R A DJUS T F O R F U RTHE R

IN FO R MA TIO N S E E: vn.

PRESSURE

CUTOFF

POINT

VARIES

OR

CHANGES

AFTER

ADJUSTING

A.

Tighten Micro-Switch attachment screws on each pressure switch.

B. LEFT PRESSURE SWITCH (1) - Observe pressure Indicated on gauge at which green indicator light cuts off. This point should be at 12 psi. If not, adjust pressure switch open at this point.

If pressure switch will not ad just, replace.

-15­

"How to Adjust Pressure

Switch", page

22.

-How to Replace

Pressure Swltch-, pa ge 22.

Detailed Trouble Shooting Chart

C. RIGHT PRESSURE SWITCH (2) Pre ssure switch should open solenoid at 14 1/2 psi and

"How to Adjus t

Pr ess ure Switch", release pressure to aproximately

13 1/2 psi. page

22.

If it does not, adjust pressure to open at

141/2 psi. "How to Replace

If pressure switch will not adjust, replace. Pressure Switch", page 22.

D.

CHECKING PRESSURE LINES AND CONNECTORS

1. Check large exhaust port hole, and adapter located inside cooker above and to the left of the charring element cavitiy. Remove back panel.

Be sure hose and adapter are not stopped up by disconnecting hose from solenoid and blowing through hose.

If there is any obstruction, replace hose and/or adapter.

2. Remove Muffler and blow through it to be sure it is not stopped up. Cl e a n to remove any obstruction.

3. Check pressure sw itch port hol e located on back of charring element housing. Be sure it Is not stopped up by disconnecting hose from pressure switches manifold and blowing through hose. If there is any obstruction, replace hose andlor adapter.

TROUBLE

VllI. WON'T

. EXHAUST

CHECK OR ADJUST

FOR FURTHER

INFORMATION SEE:

A.

Remove muffler and blow through it to be sure it is "How to Reoair Solenoid not stopped up. Crean it to remove any obstruction. '

ValVe-; page

2 ' 6 or

"How to Replace Solenoid", page 25.

B. EXHAUST HOSE - Disconnect exhaust hose from solenoid valve to muffler. Blow through it to be sure that It Is not obstructed. If it is, remove obstruction or replace hose.

C. Remove hose from solenoid bottom. Blow through solenoid to be sure it is not obstructed.

It it is, remove obstruction or replace solenoid.

D. Check large exhaust port hole and adapter located in s id e c ook er ab ove and to the left of the charring element cav ity . If

it

is obstructed, r emo ve obstruct io n or replace hose and/or adapter.

-16­

Detailed Trouble Shooting Chart

TR OUBLE CHE CK O R ADJ U S T FOR FURTHER

INFORMATION SEE:

IX . PRESSURE

BLEED OFF

TOO SLOW AT end of cook i ng cyc le. (ThIs happens either or during cooking cycle, when

Solenoid opens to relieve excess pressure. Some­ times green light will also come on.

A. Bl o w though sol enoid to be sure it is not o b struct ed, if it is, repair or replace solenoid valve.

B. Disconnect exhaust hose from bottom of solenoid exhaust valve. Blow through it to be sure it Is not obstructed. If It is, remove obstruction or replace hose.

C.

Disconnect solenoid exhaust hose from side of solenoid to muffler. Blow through it to be sure It Is not obstructed. If it is, remove obstruction or replace.

D. Check large exhaust port hole and adapter located inside cooker above and to the left of the charring element. If it is obstructed, remove obstruction or replace hose and/or adapter.

"How to Repair Sol e n oi d

Valve, page 25 or "How to

Replace SolenOid", page 26.

TROUBLE CHECK OR ADJUST x.

TIMER

SWITCH

POINTER WON1T

' MOVE " -,

A. Plug power cord into outlet with correct voltage.

Rotate timer switch through lOON· poSition and all the way around clockwise slowly to the ·Zero· time position. If timer switch is working correctly red

' (power) indicator light will light and then go off at the ·ZERO· time division: If red light does not come on, then proceed to ·C· and check.

B. If red light comes on and timer switch Is In calibration, tum timer switch pointer to

"2"

hour position and time with watch. Timer switch pointer should move one mark clockwise in 5 minutes. If pointer does not move, check to see if timer switch motor-leads are connected to TB-1 and TB-5. If they are and pointer d oe s not move, p roceed to "C".

C. Check timer switch as f ollow s:

1. Tum timer switch to ·1· hour position.

17

FOR FURTHER

INFORMATION SEE:

De t a il ed Tr ouble Shooti

9

Chart·

2.

Con nect voltmeter across T 81 and

TB -5 on terminal strip . Voltmete r should re ad 208 t o

240

VAC

±

5%.

If i t does r eplac e timer switch .

3. If it d oes not, c heck wiring up to this p oint by removing black wire t o time switch , ' from the time switch te rm i nal. Co n nec t on e l ead of v oltmeter to the end of the black wire and the o ther l ead to rel ay

R..

2 terminal. Vo ltmeter should read 208

to

240 VAC

±

5%.

If it does not, reptace wire.

If the voltmeter does read

208 to 240 VAC ±

5% at the end of the terminal, put the wire back on timer switch terminal.

-H o w to Replace Ti me r

Switc h·, p age 20.

4. T um timer switch to the -On- posltion and measure the voltage from the timer switch terminal where the orange wire Is connected to an d where the other end

Is

c on nected to

TB·5.

Th e voltm eter shou ld read 208 to 240 VAC

±

5%.

If It does not, replace the time switch. If it does, replace the orange wire and repeat

-e­

above.

-H ow to Replace TImer

Switc h·, page 20.

TROUBLE

CH ECK OR ADJUST FOR F UR THER

INF ORMA TION SEE:

XI.

CHA

TT.

EBINO

NOISE IN

BACK WHEN

T1MER IS

TURNED ON .

Note : Generally this conditiondescribes" aJ ow . voltage o r In co rre ct vo ltage ap pli ca tio n. The most common which

occurs

is the application of 120V on a 240V l ine. The resu lti ng noise

Is cau sed by the relay and solenoid trying t o -pullin · but can't becau se of insufficient voHage (both have 208 to

240V colis) . This problem i s generally caused by the plug or receetacle being wired Incorrectly.

A. VOLTAGE Check line voltage and be sure that it is

same

voltage

as

that specified on name plate

±

5%. If

It

Is, check and see If line voltage

Is applied to the L 1 nd L2 wires in power cord.

Green wire should be grounded. Sometimes on a three wire system. one half voltage (110 to 120 volts) Is applied to the cooker through error. If this Is the case, correct plug or receptacle such

-18­

~ HQW .to

, B e.p

JaceC

E lemen f', page 21. barrlng

D

etailed Trouble Shooting Chart

that correct voltage Is applied. to black and white wires in power cord.

B. Check amperage with an ..Amprobe

lt type meter by e nc ircli n g one lead to the main element. It should read no less than 20 amperes. If it reads less than

20

amperes, c hec k itA" ab o ve . ( See wiring diagram for act ual current on

L

1 and

L2).

For 3 Phase: This current reading will be · less than

5 amperes but not more than

11 amperes (See wiring diagram for actual cur­ rent on

L 1, L2, and

L3.

Wiring Diagram. pages 30. 31 and 32.

TR OUBLE CHECK OR ADJUST FOR FURTHER

INFORMATION SEE:

' ill.

TI MER S WITCH

"OFF"BUT

INDICATOR

LIGHTS

ON

DIM

AND

RELAY AND

SOLENOID

CHATTER.

Note: Generally this contion describes a charring element shorted to the ground.

In thi.s case. the charring element mayor may not heat. However,

It allows a voltage

(maximum of

120 volts) to be applied across the lights, power relay and solenoid from the other side of

240 volts (even though the timer Is off).

The low voltage Is sufficient to alow them to light dimly and to chatter. but it is not enough to fully activate them.

A. VOLTAGE -

With timer switch in the -On" position, check voltage from TB-3 to TB-4.

It should read

208 to

240

VAC ± 5%.

B. With timer switch in the

-otr position, check voltage from T8-3 to TB-4, If voltage reads up to

120 volts, replace charring element.

You may also check the charring element for ground with an, ohmmeter. To do this, remove both charring element leads from T8-3 and

TB-4 . T ouch one l ea d to one of the O h mm ete r l eads and the other Ohm mete r lead to the cook er cabinet. T hen to uch the other lead to one end of the Ohmmeter and the other lead to the Ohmmeter to the cooker cabinet. If either read zero ohms, replace charring element.

-19­

"How to Replace Charring

Elemenr, page

21.

· .

HO

W

TO RE MOVE B ACK PANELS

See Fi gure 5

To remove back panel :

1. Caution: Always rem ove plug from power out­ let before removing back panel .

2.

R emove six 1024 sc rews from back pa n el.

...........-

PT lID.

MI

CO'ID

PT lID. IMO, •

" 10.

1910, Ie

" 10. tf6O.

IICII

FIg ure 5

Removing the bottom control panel cover .

If

It

Is necessa ry to check the h eating elements , ch ange t he heating elemen ts, or cha n ge the wlr­

,ing f or different line voltage fo r the ma chine t o operate on, you must remove the bottom control panel cover. Th is panel may be seen after remov­ i ng the back cover.·

1. C auti on: Alw ays rem o ve plug from po wer o u t let before removing b a ck pane l or botto m con­ trol panel cover.

2.

To remove the bottom cont rol panel cover, sim­ ply remove the three

(3)

No.1

0

Pan Head Sheet

M etal Screws. Then the panel may be removed.

HO W T O

RE

PLACE TIMER SWITC H

Pt.

No . 1 008 • 50HZ

Pt .

No. 10 1 2 · 60 HZ

See

Figure 6

To

remove

the

time,

switch:

1.

Remove timer switch knob by pulling

if

off shaft from the front.

2. Remove back panel as outlined In -How to Re­ move Back Panel-.

20­

3. U n sc r ew two 4 -40 sc r ews f rom the f ront hold­ ing the timer switch to the face p l ate .

4. Re move timer switch and d isco nn ect black a nd oran ge wires from terminals on the timer switch .

5. Remove brown wi res fr o m time r m oto r on timerswitch from termina l strip on TB-1 and

TB -S.

6. Remove timer switch from back control box.

To l nstaJl. new timer switch: .

1.

Reconnect b ro wn wires from time r mo tor to

TB­

1 and TB-5 on terminal block.

2. Replace black wire to top spade terminal on timer switch and orange on bottom sp ade ter­ minal on timer switch. '

3. Push timer switch through the back of the fa ce

. such th at th e shaft goes through the h ole in the face pia_e.

4.

Secure t imer switch with two

4-40 screws t o the face plate.

5. Place on timer sw itch knob . Be sure th a t pointer marker on knob ma t ches with ze ro, when tim er swItch Is In the Ofr posltion. If it do es not, ad j ust by r e m oving tim er switch knob. Loosen two

4-40 s c rews . Tum tim er switch cloc kw ise or counterclockwise to align pointer wi th zer o mark on face plate.

6. C heck timer switch by plugging in power c ord

I nt o po we r recep ta cle. Then tu m t imer switch. to "'2 . hour po si tion and see if red light co mes on . lime "'m er switch- with a w atch for

5 min· ut es and see if pointer moves one mark cou n­ terclockwi se 1n 5 minutes.

7. If it does, replace bac k pan el.

TIa

MOT1It

LIMI toni LUIIS"- ... 111

LUllSILUI • •

HZ

Figure 6

!'T.

TlaaICI

--_..1

1C0. -

HOW TO REPLA

CE THER

M

OSTAT

Pt No. 1002 see

Figure 7

To remove old thermos tat:

1.

Re mov e front k nob by pulling off sh aft.

. Remove two 6-32 screws a tt achi ng therm osta t to fro nt panel.

3. R emove back p anel fr om co nsole as outlined on thi s page. -H ow To Remov e Back Panel" on page 20.

4. Remove two wi res from the thermostat te rmi­ nal. Lean cooker f orwa rd until t op front rests on floo r. .

5.

Rem ove red skirt cover .

6. Lo osen 10-24 screw holding thermostat bulb clamp. .

7. Remove thermos tat bulb.

8.

R emove thermostat.

To I ns tall new thermostat :

1. Re place old thenn ostat wi th n ew thermostat.

Th read bulb and capilla ry t ube ba ck through hole In control box in back o f cooker an d p lace bulb in the clamp on the bottom of co ok er.

2 . Ti ghten screw a n d clam p bulb In pla ce.

3 . Replace red ski rt cove r with four 10-24 scr ew s.

4. Tu m cooker right side up .

S; .

Replace wires on thermostat t erminal as per figure 7 .

'-s o

Attach thermostat to fr ont pane l with two 6-3 screws.

7 . Place thermostat knob on therm ostat. T um cold smoke switch toward green light. Pla ce pl ug in powe r o utlet. Tum timer switch knob to " 2" hour setting.

8 . Tum t he rm ostat kn o b to -BAR-SO" position .

(Amber and green Jight s sho uld come on whe n the r mostat Is turned to -BA R-B-O " posi tion.)

Ch arri ng ele men t shout d get h ot and inside of pot should get warm.

-..

--

HOW TO REPLAC

E

CHARR

I NG

ELEME

N

T

pt.

No. 1760

See

Figure

8

To remo ve old element :

1.

Re move back panel as outlin ed on page

20

H ow to Rem o ve Ba ck Pan el.

2. R emove charri ng element lead terminals from te rminal strip TB 3 a nd T8-4.

3.

Remove complete charring element by un screwing fitting with an adjustable end wrench.

This fitting is located in back of charring ele­ ment housing which is in back of cooker.

To

In s tall new ele ment:

1.

Place anti-seize compound or teflon tape on pipe threads of charring element h ous ing.

2.

Tighten charring element into place with adjust­ able end wrench.

3.

Replace electrical connections. One lead fas­ tens to TB3 on terminal stri p the othe r fast en s to TB-4 o n terminal st rip. See terminal desig­ nation on w iring diagra ms on p ages 30. 31 and

32.

4. Test by pl ugg ing power cor d into power and turni ng on ti mer switch , the ch arrin g ele ment should become hot to t ouc h Imme dia tely.

5. Repl ace bac k panel .

~

Figure 7

'-21'

Figure 8

HOWTO R

EP

LACE

PRESSURE

SWITCH

pt

No. 1003

See Figure 9

To remove old pressure swUch:

1. Remo ve back panel as outlined on page 20.

2. Remove wires (2) from pressure swItch termi­ nals.

3. Unscrew pressure switch from manifold using

314 8

open end wrench.

To

Install n ew pressure switch:

1. Screw pressu re switch on manifold usin g

314­ open end wre nch . (See Figure 9 belo w)

2. Set acco rdin g to pressure sett ing In figure 10.

(See

-How to Adjust Pr essure SWitch .

· )

3. Rep lace back panel a fter installation is com­ ple te d.

HOW TO ADJU

S

T

PRESSURE

SWITCH

pt.

No. 1003

See FJgure 10

Note: This procedure requires two people; one to observe gauge and one to make pressure setting.

It can be do n e with one person by usi ng a mir ror mou nted on lid such that ga uge can be s ee n in m irror from the back.

1. Put quart of water in cooker.

2. Place top on cooker and tighten.

3. Tum power on by setting timer switch to "1· hour .

4. Let pressure build to approximately 15 I b s.

While pressu re Is bu ilding, adjust the right side pressure switc h ( No .2) counter clockwise as vi ewed fro m to p un til solenoid releases pres­ sure.

5. Continue . to adjust until solenoid relieve pre s­ sure at between 14 to 15 psi on the ga uge in face plate (approxImately 14

1/2

psi).

6. Now relieve pressure by opening ejector v al" unti l ga ug e reads approximately 10 psi. Tum knurled adjustment screw until green light goes out (left pressure switch, No.1) at 12 psI.. The power relay will open at this point and heat Is removed. Repeat this step until this setting Is as

12 pSi.

KNURLED

WHEEL

--IMIQI

PT.......

• It..

Figure 9

-22­

Figure 10

H O W T O REP

L

ACE S I NG LE P

HASE

POWE R RE LAY

(P art No . 0317) See Figure 11

To remo ve o ld p ower r elay :

1.

Remo ve bac k panel as outlined on page

20.

~ .

Remove all wi r es from power relay term in als.

3. Re m ove d efective rela y by unscrewi ng two 8­

3 2 sc rews attaching Jt to control box .

POWER RB.AY

PT NO. 0317

To r ep la ce new power relay:

1. Atta c h new r e lay with two 8-32 scr ews to con­ trol box.

2. Replace all wires as shown in Figure 11 below.

C aution: "you use a DPDT relay, make sure that th e l ead from relay to heating element ter­ minals are on the normally open relay termi­ nals.

/ '

- /' : : ' - - - - - - - S C R EW . 1-32 x

1/2

~ PT NO .I~19

2 EA.

Figure 11

--"-IEL&Y

PT 110. 0S7

(SIIIaJ "HUE)

HOW TO REPLACE THREE PHASE' POWER RELAY

(Part No. 1511) See Figura 12

To remove old power relay:

1. Remove back panel as outlined

on

page 20.

2.

Remove all wires from po wer rela y terminals.

3. Remov e defective re lay by unsc rewi ng two

8-

32 scre ws attach ing I t to control bo x.

To replace new power relay:

1. Attach new relay with two 8-32 screws to con­ trol box.

2. Replace all wires as shown InFigure 12 below.

Caution : If you use a DP O T relay, make sure that the lead from relay to heating ele men t t er

' mlnals are on the norm ally ope n relay termi nals.

,./

~SOt!W.Hzxln

PT NO . 1319

Z!A.

Figure 12

-23­

SINGLE PHASE TO THREE PHASE CONVERSION KIT

·iPart

No. 2260 and 2265)

Single phase to three phase converison kits are available. They are part number 2260 for lower voltage

(208 240 volts , Delta) and part number 2265 for higher voltage (380/415. Wye). The kit consists of a p ower cord with

cap ,

3 pole relay,

2 element wires, and one flexible jumper to wire the elements in "Delta-. An extr . element wire is provided In

Part .~ .

, 2265 for conversion to the higher voltage for connecting from the 'Wye D neu~ral to the s yst em neutral, if required. Most

U.S. three phase installations will be a lower voltage,

208 to

240 volts (Delta). However, the cooker can be wired for a higher voltage of

415 volt CNye) operation. Mos t

In te mational installation in 3 phase will be 220 vo lts (Delta) for the lo wer volta ge. However, the cooker can be wired for

38 0 volts &lye ) operation for the hi gher vo l t age . if you nee d to convert a single unit to

3 phase, order the conversion

kit

and co nnect the elements as follo ws.

LOW VOLTAGE (208 TO 240 VOLTS)

"DELTA"

PART NO. 2260 r--------------~------------I

Figure 13

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PART NO. 2265

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-24­

HOW TO REPLACE SOLENOID VALVE

(Part No.1 004) (See Figure 15)

To re move old s ol e n oid valves:

1. Remove back panel as outlined on page 20.

2 . Remo ve lead gOing from solenoid to pressure swi t ch No .2 (right pressu re ) by disconnecting from pressure switch terminal.

3. Remove lead from solenoid to TB-5 on termi­ nal strip by disconnecting from terminal strip.

4. Disconnect hose from exhaust port to solenoid valve at the solenoid valve (bottom hose).

5: Disconnect hose from solenoid to muffler coupl. ling at the muffler connection first then discon­ nect other end of hose from solenoid.

6. Remove two 8-32 nuts attaching solenoid to mounting bracket.

7. Remove fitting from bottom of solenoid.

8. The solenoid may be repaired, if it is not other­ wise damaged (see How To Repair Solenoid, page 26) . Otherwise, replace witih new sole­ noid.

To Install new solenoid valve:

1. Replace fitting in bottom solenoid hand tight and then tighten three more turns with a 9/16 8 wrench. Then reconnect 6 8 hose to fitting.

2. Replace 6

8 hose in right side of solenoid hand tight and then tighten three more turns with a

9/16

8 wrench.

3. Mount new solenoid valve on mounting bracket with 8-32 nuts,

4, Reconnect one lead (slip on terminal) to spade terminal on pressure switch No ' , 2 (right pres­ sure switch), See Figure 9, page 22.

5. Reconnect second lead (fork terminal) to screw terminal on TB-5 on terminal strip,

6. Reconnect hose to muffler · coupling..

7. Test by putting a quart of water in cooker, placing on cooker top, and turning on cooker to see if solenoid will allow cooker to build up pressure, After pressure builds up to approxi­ mately 141/2 psi, solenoid should exhaust al­ lowing pressure to drop to apprOximately 13 112 psi, and then stop exhausting. If it needs ad­ justing, see "How to Adjust Pressure Swltch

8 on page 20,

,

r

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KTG 8AICT

fr.

NO. 1995

Figure 15

fiJ

.

/'T. NO. ...

HOSE. lG. 10"

PT. NO. 1S7~

-25­

H O W

TO

R E P AI R

S

O

LE

N O ID VALVE

( US E TE F L O N SEAL REPAIR KI T - PART NO. 1013»

T h e s ol eno id I s a v ery expensive pa rt . Ma n y tim e s it can be r epaire d at a m uch l esse r c ost than buy­ in g a n ew sole n oid. T h e r e pair s con sist of re p la c­ i ng the coli if I t is b u rnt out o r, m ost generaly re­ pla c i n g the T efl on sea l w it h a . T e fl o n Seal Kit, Pt.

N o. 101 3 . It is very I mportan t tha t the solenoid be reassembled correctJy or It will not work when put back together.

To disassemble solenoid, see Figure 16, page

27 and follow Instructions below:

1. Unscrew four

8-32 screws (Item No . 3) from

.

nuts (Item No.

16) as shown.

2. Remove screws, coD housing (Item No.6), compression ring (Item No.

10) and activator guide (Item No. 12). Then rem ove rubber dia­ phragm and Teflon seal (Items No. 13 and 14).

These last two

Items are normally together.

Once these are removed you may then look and see if the Teflon base Is stopped up. If it

Is, It must be cleaned.

Do not use old seal.

The reason for this is, once the valve has been in operation, the Teflon seal tend s to m ake a pennanent -ser and will not seal correctly. Use

Teflon Seal Repair Kit,

Pt.

No. 1013. This seal is very, very costly and runs approximately

1/3

the price of the valve.

So don't be alarmed when you purchase one. However,

It is cheaper than bu yi ng a new valve.

3.lf the co il Is good, It Is not necessa ry t o disas· semble the co li hOUSing. T o detemine whether t he co il Is good. meas u re th e contin uity b e­ tween t h e two black l eads comin g ou t o f the fr ont of th e coli hous ing wit h a d igita l vo ltme ­ t er . It s houl d r ea d

about

' 81

(} '

oom tt

. if itreads

In fi n ite ohms, the co li is bad. R eplace It by proceed i n g to P a ragrap h 4, below . If the co li is good, ski p P ara graph 4 and p roceed to re­ assemblin g so l e no id .

4. To r eplace th e co il , remove the reta i n er clip

( I tem No . 5 ). You ma y then remove th e two ends and slip the o ld coli out ( Ite m No.7

) . Re­ place with a new coli. To reassemble the coil housing, put in new colis from the bottom slid­

Ing the two black leads through the front threaded outlet Place composition paper in­ sulating rings on each end. Place plunger tube

(Item No. 20) in place then place square plate on other end. To lock In place, press the re­ tainer clip on top of the plunger. Then re­ assemble the rest of the solenoid as shown in

Figure 16, page 2 7.

-26­

To r eassemble so len o id :

1 .

Clea n b a se by so a ki ng in a str o ng s o a p so lu­ tion.

2.

After b ase is cle ane d and dried, re p lac e with new Teflon sea l (I tem No. 14) domed side up in Teflo n base ( Item No.

15) ca vi ty .

3 . Next place rubber diaphram (ltem No.

13)

In bas e cavity on to p of Teflon seal (Item No. 14) .

4 . Place activator guide (Item No. 12) in cavity on top of rubber diaphragm (Item No.

13).

5.

Place plunger activator (No.

11) in hole of acti­ vator guide (Item No. 12).

6. Place compression ring (Item No. 10) base cavity on ·top of activator guide (Item No. 12).

7.

Pla ce co mp r ession plate (Item No .9) on top of compressi on ring

(Item No . 10).

8. Place plunger pin (Item No . 8) i n coli housing

(Item No.6) hole on bottom of coil housing with little end up. Important: Little end must be up or solenoid will n ot wOrk.

9. Pl ace p lunge r (Item No.4) in hole on t op of co il h ous i ng (Item No.6).

Im po rtant:

Sma ll hole In fla t part of plu ng er s h ould be d own w it h pl!J_

og,er ..a

nd.pJ.ung.etPlo

.co

rr ~ lil.J;.§...1tle.

te. s h ould be so me g ive or "sp rin g · when p lunger pin I s p resse d a g a inst bo tto m of pl un ge r . Note:

If r e tai n ~r c lip (Item No. 5}is not in p la c e,

It wtll cause so leno id to chatter .

10. Plac e coil hou s ing asse m bly (I tem No. 6 ) o n top of Teflon base ( Item No. 15) with wire out­ let opposite hose outlet. Make s ure plunger pin (Item NO.8) remains in correct .

position in coli housing during assembly.

11. lighten assembly together by tightening four

8-32 nuts on screws.

12. Reconnect hose and wires and test as describ­ ed In ItHow to Replace Solenoid Valve", page

25 .

- .

.....

1

Fi gure 16

~ ----------------------------------------------------------------------~

HOW TO CHANGE MAIN HEATING ELEMEN

T

(Part No. 5810, BB)

(Part No. 1810,

Be & BCD)

see

Figure 17

Note: It is not n ece ssary to change elements to match voltage on whic h the unit is a ct ually operating. For exam ple. to c hange from a

240 V machine to a

2 0 8V m achine (or Just the opposite) . it is a m atter of drop­ ping one element or a dding one . See . wi ring diag r ams on pages

SO, 31 and

32 .

To determine a defect i ve elem ent, follow this procedure:

1. Remove back panel and bottom control panel cover as outtine d In.

~ow to R emove Back Panels· on page 20.

2.

Remo v e two wi res and Jump er busses from maJn ele ments . In each m achine, t h ere are four ele­ ments. Therefore. y ou must r emove eight nuts, washers, and two each sho rt jumper and long j u m per busses.

3.

Determine defective element by measuring resis­ tance with an ohmmeter. The resistance will be

37.4 ohms for a

BB and

35 ohms for a

BC and

BCD element. The element is defective if it does not read the specified ohms

±

5%. If the element is burned out, it will either measure less ohms than shown above or infinite ohms. That is. it will either show ·short to grouncr or an open circuit. In either event, the element must be rep la ced. In each model. the four elements are the sam e wattage. In the BB, each element is rated at

1540 watts at

240V.

In the

Be and BCD, each element Is 1650 watts at

240V.

To replace the element, see Figure 17 on page

29 and follow Instructions below:

1. Remove four 10-24 truss head screws from red skirt cover and remove It

2. Remove

318 nut which fasten the drain valve handle adapter to the drain valve. Pull drain valve handle and adapter forward.

3.

Remove bottom control panel assembly by remov­

Ing four .10 sheet metal screws. of the clamp band. The cl amp an d will then f lex enoug h to slip off cooker.

7. Re move the insulation from the heat c hamber only.

8. Remove two 11 420 bolts from the elem en t cla m p band. Remove element clam p and by sp reading and removing.

9. Remove defective element by sp re adi ng

and

remov­ ing .

10 . Replace defective element with good element.

11. Pla ce clam p ba n d in place and tighten two

1/4 -20

botts .

12.

Replace heat chamber insulation.

13. Replace insulation cfamp band by bolting two

1/4­

20 on the front lips then fasten to the top with three

10-24 nuts.

14. Replace element end cap by fastening to ins ulati o ' clamp band with four '10 sheet metal screws.

. 15. Rep l ace botto m control panel assembly by fasten­

Ing to the In sulation clamp band with four s h eet metal screws.

16.

Replace bottom cabinet assem bly ( with casters) and fasten to the top with nine 10-24 truss he ad scr e ws.

17.

Replace drain valve handle and adapter by screw­

Ing

318 nut onto drain valve stem. Align handle by

Joosenlng the alignment nut correctty positioning the drain valve handle. If the drain valve

Is closed, the correct position Is horizontal to the cabinet and to the right.

18.

Fasten red skirt cover to bottom of cooker cabinet with four

10-24 screws.

4. Remove element end cap by r e mov ing four .10 sheet metal screws.

19. Tum cooker back over on its caste rs and reconnect wi res and jumpers for the p roper volt age. See, 'WIr­ ing D lag ram-, pages 30 ,31 and 32.

5. Remove nine 10-24 truss head sc rews wh ich f as­ ten the top to the bottom cabinet assembly and re­ move bottom cabinet assembly.

20.

Test unit with a quart of water and make any neces­ sary adjustments to the pressure switch to be sur that they are adjusted to the proper values.

6. Remove insulation clamp band by removing three

10-24 nuts holding the Insulation clamp band to the top. Th en re m o ve tw o

1 /4-20

bo lts fr om th e front

-28

21. Fasten bottom control panel cover and back panel back I n place .

Figure 17

- -

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ADAPTER. · 51,4 , PRESSURE SWI TCH ).IANIF

OLD,

PT NO . 1540

PRESS URE

SW ITCH, SlNCLE, PT NO . 100.1

SOLENOID VAllIE . PT NO ; 1

OO~

H OSE , LG, 6", PT NO. 156

EL BOW, !..C, lilT, PT NO. 111

UO ASSV . COMPlETE

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BACK. CABINET SKIRT

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advertisement

Key Features

  • Pressure baking and smoking
  • Hickory-smoked flavor
  • Independent pot controls
  • Flexible loading and timing
  • Adjustable voltage (208 or 240 VAC)
  • Multiple sizes (BB, BC, BCD)
  • Safety pressure relief valve

Related manuals

Frequently Answers and Questions

What is the difference between the BB71 and BB73 models?
The only difference between the BB71 and BB73 models is the phase. The BB71 is a single phase unit and the BB73 is a three phase unit.
How do I change the voltage on the Smokaroma BBQ?
All models can be changed to either 208 VAC or 240 VAC in the field. If the voltage is not specified when ordered, the unit will be wired for 208 VAC at the factory. To change to 240 VAC, disconnect the top element.
How do I clean the Smokaroma BBQ?
At the end of each day, completely clean the interior. Pour 1 quart of water on the bottom and add detergent. Scour with a scotch Brite maroon pad. Drain water and dry thoroughly.
How do I adjust the pressure switch?
The pressure switch can be adjusted to control the pressure cut-off point and the exhaust point. Refer to the service manual (page 22) for instructions.
What is the purpose of the copper "Chore Boy" filter?
The filter is located inside the exhaust port and prevents food particles from entering the exhaust system and clogging the lines. Change the filter at least once per month and more often with heavy usage.
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