Service Manual
Contents
1. OORE 0 44 ese Suv 36 Smokaroma 18 MODELS 88 AND BC THE WING DIAGRAM BELOW 5 WIRED FOR HIGH VOLTAGE THREE PHASE WENS E AND F BELOW FOR CONNECTIONS TO CHANGE TO A LOW VOLTAGE THREE PHASE DELTA Spapal 5 595 48 gsz 4542 195 ark a 240 ew a eee ee OR 220 VOLT CPERATIN 3 PHASE 372. SERVICE MANUAL INC 6 COPYRIGHT 2007 SMOKAROMA INC MODELS BB BC BCD SMOKAROMA INC BOX 25 62 BAR B O AVENUE BOLEY OKLAHOMA 74829 PHONE 918 667 3341 800 331 5565 WWW Smokaroma com info smokaroma com Description of Models This service manual is written for models BB BC and QCD series There are two models for each series r example in the BB series there are models BB71 BB73 The only difference between the two Is the phase On models the model designated 71 is single phase unit and the model designated 737 is phase unit All models can be changed in the field to either 208 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 Asingle phase unit may be changed to 3 phase with a change of cord and relay This may be ordered as a modification 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 5 8 The BC is an Smokaroma barbequer combines the modern sci entific method of pressure baking with pressure smok ing to get that old fashion hickory smoke flavor does this economically automatically and in a fraction of the time to prepare barbeque by ordinary methods In
3. SCREW 8 52 X 1 2 PT NO 1519 2 EA Figure 11 HOW TO REPLACE THREE PHASE POWER RELAY Part No 1511 See Figure 12 To remove old power relay To replace new power relay 1 Remove back panel as outlined on page 20 1 Attach new relay with two 8 32 screws to con 2 Remove all wires from power relay terminals trol box 3 Remove defective relay by unscrewing two 8 2 Replace all wires as shown inFigure 12 below 32 screws attaching It to contro box Caution you use DPDT relay make sure that the lead from relay to heating element ter minals are on the normally open relay termi nals SCREW 8 52 X 1 2 PT 1319 2 Figure 12 23 SINGLE PHASE TO THREE PHASE CONVERSION KIT Part No 2260 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 power 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 No 2265 for conversion to the higher voltage for connecting from the Wye _ neutral to the system 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 Wye operation Most intemational installation in 3 phase will be 220 volts D
4. filter at least once per month and more often with heavy usage Controls amp Figure 2 1 Timer Switch Provides timed on off main switch All lights should come on when first turned on if thermostat is in Bar B Q 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 at prevention control When set at Bar B Q position thermostat will cut out at a bottom tem perature of 550 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 F the thermostat will automatically cut back on 4 Amber Neon Indicator Light Temperature Indicated voltage is being applied through thermo stat to heating elements 5 Cold Smoke Switch Provides Cold Hot Smoke mode In the Off 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 B Q In the On or up position the unit is in the Hot Smoke mode The main elements will provide heat along with the Charring Element The green light will be on with amber and red when
5. 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 amp Controls The following is a method of performing quick checks on the Bar B Q Boss to see if it is functioning worrectly It mainly 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 Bar B Q 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 fight and then go off when the pointer on the time switch reaches 0 time Possible Troubles f these things do not happen it may indicate one or more of the following troubles SYMPTOMS POSSIBLE TROUBLES TO REPAIR SEE a No indicator lights come on 1 Assuming correct voitage is 4 Won t Heat Detailed available at the outlet defective Trouble Shooting Chart wiring in power c
6. 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 2 CLEANLINESS IS 90 OF MAINTENANCE MONTHLY 1 Observe pressure cut off point Green light should cut off at 12 psi If not see service manual page 22 for adjustment Observe pressure exhaust point Exhaust should occur at between 14 to 15 psi not see service manual page 22 for adjustment Observe timer cut off point Dial should point to Zero at cut off point If not remove dial knob and adjust 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 Tighten any loose nuts bolts or screws If ejector valve leaks replace it 7 Do not tamper with safety valve If it leaks re place it Examine units for any broken missing or de teriorated parts Replace immediately do not operate a defective condition Change Chore Boy
7. the timer is set and the thermostat is set to Bar B Q However the green light will cycle off when approximately 12 psi is reached and on when pressure drops below 10 psi Functions 6 Green Neon Indicator Light 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 vaive for relieving pressure should it ex ceed 17 psi Resets at 15 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
8. DRAIN VALVE NO 0722 DRAIN VALVE ADAPTER ASSY PT NO 1595 ADJ DRAIN VALVE BRKT PT NO 2037 CABINET SKIRT RED PT NO 5936 BB PT NO 1938 BC PT NO 6955 BCO DRAIN VALVE KNOB PT NO 0720 ORAIN HANDLE PT NO 2056 EACH SKIRT COVER RED PT NO 6035 2035 BC amp BCD DRAWER SLIDE RED RIGHT DRAWER SLIDE RED LEFT _ 2 NO 2030 PT NO 2025 DRAIN PAN 1528 BS 234 AMPERES 25 6 220 205 640 VOLTS BC 252 AMPERES 8 6 VOLTS 287 6 22 KLIS 222 EMO WILTS 74 FOR SAFETY GROUND EARTH CANET 432 a PHASE RE A CORD AVALABLE FROM FACTORY DARAH CONNECTIONS CHANGE 0 THREE PHASE DELTA 825 32 5 5 E Spel 5 FHT E TEHE Bg 7 REV ne 33 74 BE 54 AMPERES 6208 VOLTS AND 7 2 AMPERES 6220 VOLTS AND 7 9 AMPERES 6041 MODEL 8 7 3 AMPERES 208 VOLTS AMD 7 7 AMPERES 220 VOLTS AND 84 AMPERES 6040 MODEL 88 4 AMPERES 0208 VOLTS AND 102 AMPERES 0220 VOLTS AND 7 4 AMPERES 6240 MODEL BC 103 AMPERES 208 VOLTS AND
9. and white wires in power cord B Check amperage with an Amprobe type meter by encircling one lead to the main element It should read less than 20 amperes If it reads less than 20 amperes check A above See wiring ia a for actual current on L1 and L2 For Phase This current reading will be less than 5 amperes but not more than 11 amperes See wiring diagram for actual cur rent on L1 L2 and L3 CHECK OR ADJUST Note Generally this contion describes a charring element shorted to the ground In this case the charring element may or 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 position check voltage from TB 3 to TB 4 It should read 208 to 240 5 B With timer switch in the Off position check voltage from TB 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 TB 3 and TB 4 Touch one lead to one of the Ohmmeter leads and the other Ohmmeter lead to the cooker cabinet Then touch the other lead to one end of the Ohmmeter and the other lead
10. 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 continuity replace the lead Repeat this process for R 7 and R 8 If voltmeter reads line voltage across the terminals of any of the elements and any one element does not heat re move connections the element and check the resis tance with the ohmmeter of each element The resistance should read 35 ohms 5 for the BC 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 Detailed Trouble Shooting Chart 3OUBLE w HEATS ONLY WARM AND PRESSURE BUILDS UP EXCEEDINGLY SLOW CHECK OR ADJUST VOLTAGE Check line voltage and be sure that the voltage is same as specified on nameplate 5 If itis check and see if 208 to 240 VAC 5 is applied to the L1 and L2 wires in power cord 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 L1 and L2 wires in power cord For 3 Phase Line voltage should appear between L1 and L2 L1 and L3 and L2 and L3 Check amperage with Amprobe type meter by encircling one lead to main elements It should read not less than 20 amperes See Wiring Diagram page 30 for a
11. band clamp and will then flex enough to slip off cooker Remove the insulation from the heat chamber only Remove two 1 4 20 bolts from the element clamp band Remove element clamp and by spreading and removing Remove defective element by spreading and remov ing Replace defective element with good element Place clamp band in place and tighten two 1 4 20 bolts Replace heat chamber insulation Replace insulation clamp band by bolting two 1 4 20 on the front lips then fasten to the top with three 10 24 nuts Replace element end cap by fastening to insulatio clamp band with four 10 sheet metal screws Replace bottom control panel assembly by fasten ing to the insulation clamp band with four sheet metal screws Replace bottom cabinet assembly with casters and fasten to the top with nine 10 24 truss head screws Replace drain valve handle and adapter by screw ing 3 8 nut onto drain stem Align handie by loosening the alignment nut correctly positioning the drain handle the drain valve is closed the correct position is horizontal to the cabinet and to the right Fasten red skirt cover to bottom of cooker cabinet with four 10 24 screws Turn cooker back over on its casters and reconnect wires and Jumpers for the proper voltage See Wir ing Diagram pages 30 31 and 32 Test unit with a quart of water and make any neces sary adjustments to the pressure switch to b
12. only be done when cooker is cold or froma cold start 1 Rotate thermostat to the 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 lower side of cooker to see if it becomes warm when the cooker is it may take several minutes before the side becomes warm to the touch Possible Trouble If these things do not happen it may indicate one more of the following problems SYMPTOMS POSSIBLE TROUBLES TO REPAIR SEE e Charring Element does not 1 Defective wiring For all troubles listed here see become warm IV Won t Create Smoke Detailed Trouble Shooting Chart page 13 2 Defective Thermostat 3 Defective Charring Element f Side of cooker does not 1 Defective wiring For all troubles listed here see warm Won t Heat Detailed Trouble Shooting page 8 2 Defective Power Relay 3 Defective Main Elements Note This unit has four separate elements Therefore 4 Cold Smoke Switch must be it s rare that all elements will in UP position and green light burn out at once unless an over is on voltage has been applied Most likely the wires from the power relay are defective Assuming that all controls parts are functioning c
13. operation as a barbequer a smail 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 5 Ibs 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 in the slots to the upright position Then the _ 9 is rotated clockwise until stops The remaining Clamp bolts 2 on the BB and 4 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 Description of Operation intermediate size pot and has six 6 clamp down knobs top It has an inside pot diameter of 14 5 8 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 in
14. release pressure to approximately 13 1 2 psi If it does not adjust pressure to open at How to Replace Pressure 14 1 2 psi If pressure switch will not adjust Switch page 22 replace THERMOSTAT The thermostat is designed How to Replace to prevent overheating and possible damage Thermostat page 21 to unit It is designed to cut off at a temperature of 550 F at point on which the thermostat bulb is mounted Rotate thermostat knob slowly toward Thermostat should click off somewhere between hold and off position at approximately the 2 00 o clock position M3 Detailed Trouble Shooting Chart TROUBLE CHECK OR ADJUST FOR FURTHER INFORMATION SEE MAIN ELEMENTS Check element connection Rewire Connections configuration to see if they are wired for the Wiring Diagram 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 Wye configuration F POWER RELAY Power relay should be normally to Replace Power open when no voltage is applied You should be Relay page 23
15. release pressure to aproximately 13 1 2 psi page 22 If it does not adjust pressure to open at 14 1 2 psi 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 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 Clean to remove any obstruction 3 Check pressure switch port hole 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 and or adapter TROUBLE CHECK OR ADJUST FOR FURTHER INFORMATION SEE WON T A Remove muffler and blow through it to be sure itis How to Repair Solenoid EXHAUST not stopped up Clean it to remove any obstruction Valve page 26 or How to Replace Solenoid page 25 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 rem
16. timer switch Switch 20 terminal where the orange wire is connected to and where the other 15 connected to 5 The voltmeter should read 208 to 240 VAC 5 If it does not replace the time switch If it does replace the orange wire and repeat above TROUBLE CHECK OR ADJUST FOR FURTHER INFORMATION SEE XI CHATTERING Note Generally this condition describes How to Replace Charring NOISE IN voltage or incorrect voltage application The most Element page 21 BACK WHEN common which occurs is the application of 120V TIMER IS on a 240V line The resulting noise is caused by TURNED ON the relay and solenoid trying to pull but can t because of insufficient voltage both have 208 to 240V coils This problem is generally caused by the plug or receptacle 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 L1 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 Detailed Trouble Shooting Chart TROUBLE SWITCH LIGHTS ON DIM AND RELAY AND SOLENOID CHATTER that correct voltage is applied to black
17. to the Ohmmeter to the cooker cabinet If either read zero ohms replace charring element 18 Wiring Diagram pages 30 31 and 32 FOR FURTHER INFORMATION SEE How to Replace Charring Element page 21 HOW REMOVE BACK PANELS See Figure 5 To remove back panel 1 Caution Always remove plug from power out let before removing back panel 2 Remove six 10 24 screws from back panel Removing the bottom control panel cover If it is necessary to check the heating elements change the heating elements or change the wir ing for different line voltage for the machine to operate on you must remove the bottom control panel cover This panel may be seen after remov ing the back cover 1 Caution Always remove plug from power out let before removing back panel or bottom con trol panei cover 2 To remove the bottom control panel cover sim ply remove the three 3 No 10 Pan Head Sheet Metal Screws Then the panel may be removed HOW TO REPLACE TIMER SWITCH Pt No 1008 50HZ No 1012 60 HZ See Figure 6 To remove the timer 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 6 Unscrew two 4 40 screws from the front hold ing the timer switch to the face plate Remove timer switch and disconnect black and orange wires from terminals on the timer switch Remove brown wi
18. 10 9 AMPERES 8020 VOLTS AND 7 9 AMPERES 240 MODEL 88 10 0 AMPERES 208 VOLTS AND 10 6 AMPERES 6220 VOLTS AND 7 9 AMPERES 6040 MODEL BC 107 AMPERES 208 VOLTS AND 11 3 ANPERES 6720 VOLTS 84 AMPERES 6040 VOL 208 220 240 WLS OLY FOR SAFETY URRI GROUND 10 _ SET LEFT PRESSURE MH WHERE 6120 30 3 Smokaroma 6 LADDER SCHEMATIC DIAGRAM MODELS 86 AND BC THE WRING DIAGRAM BELOW FOR LOW VOLTAGE THREE PHASE DELTA SEE MENS E F BELOW FOR CONNECTIONS TO CHANGE TO HIGH VOLTAGE THREE PHASE WYE 5 Ipe FEE 8369 858 al ay H 8 PHAS 208 OR 220 VOLT OPERATION COPYRIGHT 12 24 98 REV DATE 02 23 01 88 56 AMPERES 6 50 ELT AD 64 6 5 BC 67 AMPERES 6 380 WITS 69 AMPERES 8 45 LIS WEL BB 11 1 AMPERES 30 WLIS 64 AMPERES 415 WALTS BC 113 AMPERES 380 AND amp 9 AMPERES 415 WATS WODEL 88 53 AMPERES 6 380 WATS AND 7 2 AMPERES 415 VOLTS 7 4 AMPERES 6 380 AND 7 7 415 VOLTS 7 05 KLIS 50 KLIS 24 45 iy 5 e i 5 URES POWER
19. 2 and A3 above 2 One or more Main Elements is defective 1 Pressure setting is too high 1 Pressure Switch setting is too high or low 2 Defective solenoid 3 Pressure line stopped up TO REPAIR SEE Ill Heats But Won t Build Pressure Detailed Trouble Shooting Chart page 12 Heats Only Warm Detailed Trouble Shooting Chart page 11 How to Adjust Pressure Switch page 22 How to Adjust Pressure Switch page 22 VII Won t Exhaust Detailed Trouble Shooting Chart page 16 Detailed Trouble Shooting Chart FOREWORD TO THE DETAILED TROUBLE SHOOTING CHART LIST The Detailed Trouble Shooting Chart list the Trouble what to Check or Adjust and what further need to do to fix it under For Information See We tried to list the Trouble just as the customer wouk experience or say it The most prevalent trouble Won t Heat 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
20. CH KNOB NO 1530 SS tens KNOB PT NO 1531 COLO SMOKE SWITCH PT 1510 GAUGE PRESSURE 1870 LIGHT WHITE PT 1523 CHARRING CUP NO ue CHARRING ELEMENT LONG NO 17 1728 NO 1108 1720 ON 88 EACH BC amp 12 EACH ON BCD 1710 4 amp 12 EACH BCD JUMPER BUSS SHORT 1897 2 EACH ON amp BC 4 EACH RCD JUMPER BUSS 1895 2 EACH ON amp 4 EACH ON BCD ELEMENT MAIN 1540 WATTS BB 5810 ELEMENT MAIN 1850 WATTS BC BCD PT NO 1810 4 EACH ON 88 EACH ON BCD 1875 CLEMENT CLAN BAND 5985 1885 BC amp BCD ay KERT qoen SIDE BRKT LT L NO 1950 BOT CONTROL COVER BOTTON _ 1955 5960 88 1860 NO 6980 BCD BACK CABINET SKIRT BA PT NO 5937 BB PT NO 1937 BC NO 6937 BCD CASTER RIGID 0718 eee 2 EACH CASTER SWIVEL W BRAKE PT NO 0719 2 N ELEMENT END CAP 1940 INSULATION CLAMP BAND NO 5970 88 NO 1870 amp ACD P 2 P TOP HOLDER BRACKET PT NO 1975 CABINET BOTTON _ NO 5920 BA 1920 6920 BCD
21. 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 place Controls amp 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 19 Main Elements Provides main source of heat Each element is rated at 1540 watts 240V for the BB and 1650 watts 240V for the BC 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 20 Exhaust Solenoid Provides valve to exhaust steam automatically 1 9 g H 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 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 thereby adding heat
22. WITCH 2 Pressure switch should open solenoid at 14 1 2 psi and release pressure to approximately 13 1 2 psi if it does not adjust pressure switch to open at 14 1 2 psi pressure switch will not adjust replace POWER RELAY Power Relay should be normally open when no voltage is applied You should be able to move the contactor from the normally closed position with your fingers make sure power cord is removed before trying this If the contacts are welded in the normally closed position replace relay If contact points are badly pitted replace power relay CHECK OR ADJUST A Tighten Micro Switch attachment screws on each pressure switch 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 adjust replace 15 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 Replace Power Relay page 23 FOR FURTHER INFORMATION SEE How to Adjust Pressure Switch page 22 How to Replace Pressure Switch page 22 Detailed Trouble Shooting Chart RIGHT PRESSURE SWITCH 2 Pressure How to Adjust switch should open solenoid at 14 1 2 psi and Pressure Switch
23. able to move the contactor from the normally closed position with your fingers 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 CHECK OR ADJUST FOR FURTHER INFORMATION SEE VI PRESSURE A CHECKING PRESSURE LINES AND CONNECTORS BUILDS UP 1 Check large exhaust port hole and adapter HIGH located inside cooker above and to the of the charring element cavity 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 Clean to remove any obstruction 3 Check pressure switch port hole located on back 14 Detailed Trouble Shooting Chart TROUBLE VII PRESSURE CUT OFF POINT VARIES OR CHANGES AFTER ADJUSTING 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 and or adapter LEFT PRESSURE SWITCH 1 Observe pressure Indicated on gauge at which pressure indicator light green cuts off This point should be at 12 psi If not adjust pressure switch to open at this point If pressure switch will not adjust replace RIGHT PRESSURE S
24. ay and the element terminal on the right side of the elements The voltmeter should read line voitage 5 If it does not replace the lead on the right side If the voltmeter reads line voltages across the terminal of the elements and any one 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 1 and lead two 2 lead 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
25. ctual current L1 and L2 it reads less than 20 amperes recheck A above and then proceed to below For 3 phase This current reading should not be less than amperes but not more than 11 ampheres See Wiring Diagrams pages 31 and 32 for actual current on L1 L2 and L3 MAIN ELEMENTS With the timer switch and the thermostat rotated to Bar B Q 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 4 Won t Heat Detailed Trouble Shooting Chart then correct defective parts If the 208 to 240 VAC 5 appears across terminals of main elements proceed to 41 Won t Heat Detailed Trouble Shooting Chart 11 FOR FURTHER INFORMATION SEE Wiring Diagram pages 30 31 and 32 Wiring Diagram pages 30 31 and 32 How to Replace Main Element page 29 Detailed Trouble Shooting Chart TROUBLE CHECK OR ADJUST FOR FURTHER INFORMATION SEE HEATS BUT A GAUGE Check for leaks around gauge WON T BUILD connections If loose tighten Check gauge PRESSURE to see if pointer is unobstructed If defective replace gauge EJECTOR VALVE When stem is down ejector valve should be closed and pressure tight If the ejector valve leaks replace SAFETY VALVE Safety valve should function at 17 1 psi It will then reset itself at approxi mately 15 psi If the safe
26. e sur that they are adjusted to the proper values Fasten bottom control panel cover and back panel back in place 05 LID 55 COMPLETE W HANDLE amp O RING ADAPTER Si PRESSURE SWITCH MANIFOLD PT NO 1540 PRESSURE SWITCH SINGLE PT 1003 SOLENOID VALVE 1004 HOSE LG 5 PT NO 156 ELBOW LG 907 PT 111 ADAPTER STRAIGHT LG PT NO 1108 HOSE LG 87 1573 7 ADAPTER STRAIGHT LG NO 1108 ADAPTER ELBOW PT 2040 HOSE 7 SMALL PT 0726 ADAPTER ELBOW PT NO 2040 HOSE 7 SMALL NO 0726 ADAPTER ELBOW PT NO 1110 MANIFOLD ASSY INSERT PT NO ADAPTER STRAIGHT LG PT HOSE 10 LG 1573 ADAPTER STRAIGHT LG 1108 KNOB CLAMP DOWN NO 4 EACH HEATING CHAMBER FACH BB BC EACH ON BCD BOTTOM CONTROL PANEL a NO CONTROL BOK ASSY NO 1595 POWER RELAY NO 0317 HANDLE W SCREWS 2076 PT NO 1815 TERMINAL STRIP NO 11 SAFETY VALVE PT NO 0075 EJECTOR VALVE PT NO 0065 MUFFLER TUBE PT NO 2060 O RING NO 1825 THERMOSTAT 1002 TIMER SWITCH PT NO 1012 60 HERTZ PT NO 1008 50 HERTZ FACEPLATE NO 1980 LIGHT RED 1521 UGHT AMBER 1522 UGHT GREEN 1520 TIMER SWIT
27. elta for the lower voltage However the cooker can be wired for 380 volts Wye operation for the higher voltage if you need to convert a single unit to 3 phase order the conversion kit and connect the elements as follows LOW VOLTAGE 208 TO 240 VOLTS DELTA PART NO 2260 LOW VOLTAGE 380 415 VOLTS WYE PART NO 2265 el HOW REPLACE SOLENOID VALVE Part No 1004 See Figure 15 To install new solenoid valve To remove old solenoid valves 1 Remove back panel as outlined on page 20 2 Remove lead going from solenoid to pressure switch No 2 right pressure by disconnecting from pressure switch terminal Remove lead from solenoid to TB 5 on termi nal strip by disconnecting from terminal strip Disconnect hose from exhaust port to solenoid valve at the solenoid valve bottom hose Disconnect hose from solenoid to muffler coupl ling at the muffler connection first then discon nect other end of hose from solenoid 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 Figure 15 1 2 HOSE LG 10 1575 25 Replace fitting in bottom solenoid hand tigh
28. emove Back Panel on page 20 4 Remove two wires from the thermostat termi nal Lean cooker forward until top front rests on floor 5 Remove red skirt cover 6 Loosen 10 24 screw holding thermostat bulb clamp 7 Remove thermostat bulb 8 Remove thermostat To Install new thermostat 1 Replace old thermostat with new thermostat Thread bulb and capillary tube back through hole In control box in back of cooker and place bulb in the clamp on the bottom of cooker Tighten screw and clamp bulb place Replace red skirt cover with four 10 24 screws Turn cooker right side up Replace wires on thermostat terminal as per figure 7 76 Attach thermostat to front panel with two 6 3 screws 7 Place thermostat knob on thermostat Turn cold smoke switch toward green light Place plug in power outlet Turn timer switch knob to 2 hour setting 8 Turn thermostat knob to BAR B Q position Amber and green lights should come on when thermostat is turned to BAR B Q position Charring element should get hot and inside of pot shouid get warm Figure 7 CHARRING ELEMENT Pt No 1760 See Figure 8 To remove old element 1 Remove back panel as outlined on page 20 How to Remove Back Panel 2 Remove charring element lead terminals from terminal strip TB 3 and 4 3 Remove complete charring element by un screwing fitting with an ad
29. g 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 concemed all the mod els have the same circuitry and operate the same Therefore the service will be substantially the same all three models The only difference in the models are size and wattage These difference will be pointed out in the service manual BCD 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 initial 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 coo
30. g Chart TROUBLE WON T 5 TROUBLE OVERHEATS CHECK OR ADJUST FOR FURTHER A INFORMATION SEE VOLTAGE With time switch set at 1 hour and thermostat at Bar B Q position check volt age across TB 2 and TB 5 Line voltage should appear If not voltage should be checked as specified In A through E under Won t trouble CHARRING ELEMENT 11208 to 240 VAC How to Replace 5 appears across TB 2 and 5 the Charring Element charring element should heat If it does not page 21 check for loose terminals If are found replace charring element Alternate Check the resistance of the charring element with an ohmmeter It should read 250 ohms 10 If it does not replace the charring element CHECK OR ADJUST FOR FURTHER A INFORMATION SEE 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 LEFT PRESSURE SWITCH 1 Pressure How to Adjust Pressure switch should cut off at 12 psi If it does not Switch page 22 adjust pressure switch to cut off at this pressure If pressure switch will not adjust How to Replace Pressure replace Switch page 22 RIGHT PRESSURE SWITCH 2 Pressure How to Adjust Pressure switch should open solenoid at 14 1 2 psi and Switch page 22
31. ger pin correctly in place there should be some give or spring when plunger pin is pressed against bottom of plunger Note If retainer clip No 5 is notin place it will cause solenoid to chatter 10 Place coil housing assembly Item No 6 on 11 12 top of Teflon base Item No 15 with wire out let opposite hose outlet Make sure plunger pin Item 8 remains correct_position in coil housing during assembly Tighten assembly together by tightening four 8 32 nuts on screws w Reconnect hose and wires and test as describ ed in How to Replace Solenoid Valve 25 3 Clean base by soaking in a strong soap solu HOW CHANGE MAIN HEATING ELEMENTS Part No 5810 BB Part No 1810 BC amp BCD See Figure 17 Note It is not necessary to change elements to match voltage on which the unit is actually operating For example to change from a 240V machine to a 208V machine or just the opposite it is a matter drop ping one element or adding one See wiring diagrams on pages 30 31 and 32 To determine a defective element follow this procedure 1 Remove back panel and bottom control panel cover as outlined in to Remove Back Panels page 20 Remove two wires and jumper busses from main elements In each machine there are four ele ments Therefore you must remove eight nuts washers and two each short jumper and long jumper b
32. il out Item No 7 Re place with a new To reassemble the coil housing put in new coils 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 27 26 To reassemble solenoid tion After base is cleaned and dried replace with new Teflon seal Item No 14 domed side up in Teflon base item No 15 cavity Next place rubber diaphram No 13 in base cavity on top of seal Item No 14 Place activator guide No 12 in cavity on top of rubber diaphragm No 13 Place plunger activator No 11 in hole of acti vator guide Item No 12 Place compression ring Item No 10 base cavity on top of activator guide Item No 12 Place compression plate Item No 9 on top of compression ring Item No 10 Place plunger pin Item No 8 in coil housing gt No 6 hole on bottom of coil housing with little end up Important Little end must be up or solenoid will not work Place plunger Item No 4 in hole on top of coil housing Item No 6 Important Small hole in flat part of plunger should be down with plunger and plun
33. itch to 1 hour position 2 Connect voltmeter across TB 1 and TB 5 on _ Wiring Diagram terminal strip Voltmeter should read 208 to pages 30 31 and 32 240 VAC 5 If it does proceed to E 3 If it does not check wiring up to this point Wiring Diagram on by removing black wire to timer switch from pages 30 31 32 WwW 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 5 If it does not replace black wire 8 4 Turn timer switch to the position and measure the voltage from the timer switch terminal where the orange wire is connected and TB 5 The voltmeter should read 208 to 240 5 If it does not replace the timer switch If it does connect voltmeter across TB 1and TB 5 on terminal strip Voltmeter should read 208 to 240 VAC 5 If it does not replace orange wire If it does proceed to E below THERMOSTAT The thermostat should be the BAR B Q position Check the voltage between TB 2 and TB 5 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 208 to 240 VAC 5 appears then check and see if it appears between the thermostat terminal on which the black and wh
34. ite striped wire is connected and 5 If it does not replace the thermostat If 208 to 240 VAC 5 appears then proceed to 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 should 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 below and check POWER RELAY Check the voltage with volt meter between terminals R 4 and R 5 on the power relay coil Voltmeter should read 208 to 240 5 If it does and the relay is energized replace the relay If the voltmeter does not read 208 to 240 VAC 5 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 5 If the relay is energized and elements do not heat proceed to H and check 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 a
35. justable end wrench This fitting is located in back of charring ele ment housing which is in back of cooker To Install new element 1 Place anti seize compound or teflon tape on pipe threads of charring element housing 2 Tighten charring element into place with adjust able end wrench 3 Replace electrical connections One lead fas tens to TB 3 on terminal strip the other fastens to TB 4 on terminal strip See terminal desig nation on wiring diagrams on pages 30 31 and 32 4 Test by plugging power cord into power and turning on timer switch the charring element should become hot to touch immediately 5 Replace back panel Figure 8 HOW ADJUST PRESSURE SWITCH PRESSURE SWITCH Pt No 1003 Pt No 1003 10 Note This procedure requires two people one to observe gauge and one to make pressure setting It can be done with one person by using a mirror mounted on lid such that gauge can be seen in mirror from the back To remove old pressure switch 1 Remove back panel as outlined on page 20 2 Remove wires 2 from pressure switch termi 1 Put quart of water cooker 3 Unscrew pressure switch from manifold using 3 4 open end wrench 2 Place top on cooker and tighten 3 Turn power on by setting timer switch to 1 To Install new pressure switch hour 1 Screw pressure switch on manifold using 3 4 4 Let pressure build t
36. king 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 Smokaroma Preventive 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 ail the smoke stain off the cooker Itis 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 COPPER FILTER CHORE BOY PT
37. n 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 and check If red light comes on and timer switch is in calibration turn 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 1 and TB 5 If they are and pointer does not move _ proceed Check timer switch as follows 1 Turn timer switch to 1 hour position of Fu Detailed Trouble Shooting Chart 2 Connect voltmeter across TB 1 and TB 5 on How to Replace Timer terminal strip Voltmeter should read 208 to Switch page 20 240 VAC 5 If it does replace timer switch 3 If it does not check wiring up to this point by removing black wire to time switch from the time switch terminal Connect one lead of voltmeter to the end of the black wire and the other lead to relay R 2 terminal Voltmeter should read 208 to 240 VAC 5 If it does not replace 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 4 Turn timer switch to the On position and How to Replace Timer measure the voitage from the
38. nd 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 Replace Timer Switch on page 20 How to Replace Thermostat page 21 See Wiring Diagram pages 30 31 and 32 Wiring Diagram on pages 30 31 and 32 How to Adjust Pressure Switch page 22 How to Replace Pressure Switch page 22 Wiring Diagram on pages 30 31 and 32 and How to Replace Power Relay page 23 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 8 and between R 7 and R 8 Voltage should be the same in each case as that specified by the name plate 5 Single Phase Cont Check the voltage at the How to Replace Heating element terminals where the leads are connected Element page 29 The voltmeter should read 208 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 rel
39. o approximately 15 Ibs open end wrench See Figure 9 below While pressure is bullding adjust the right side pressure switch No 2 counterclockwise as 2 Set according to pressure setting in figure 10 viewed from top until solenoid releases pres See How to Adjust Pressure Switch sure 3 Replace back panel after installation is com 5 Continue to adjust until solenoid relieve pres pleted sure at between 14 to 15 psi on the gauge in face plate approximately 14 1 2 psi 6 Now relieve pressure by opening ejector valv until gauge reads approximately 10 psi knurled adjustment screw until green light goes out left pressure switch No 1 at 12 The power relay will open at this point and heat is removed Repeat this step until this setting is as 12 psi KNURLED WHEEL DECREASE Figure 10 Figure 9 HOW REPLACE SINGLE PHASE POWER RELAY Part No 0317 See Figure 11 To remove old power relay To replace new power relay 1 Remove back panel as outlined on page 20 1 Attach new relay with two 8 32 screws to con __4 Remove all wires from power relay terminals trol box 3 Remove defective relay by unscrewing two 8 32 screws attaching It to control box 2 Replace all wires as shown in Figure 11 below Caution you use a DPDT relay make sure POWER RELAY that the lead from relay to heating element ter PT NO 0317 minals the normally open relay termi nals
40. ord page 8 and Wiring Diagram pages 31 32 and 33 2 Defective wiring in control box Won t Heat Detailed Trouble Shooting Chart page 8 and Wiring Diagram pages 31 32 and 33 3 Defective timer switch Won t Heat 0 Detailed Trouble Shooting Chart page 8 and How Replace Timer Switch page 20 4 Defective lights Exploded Parts Sheet page 30 b Power light comes on 1 Defective wiring Wiring diagram pages 31 32 but Amber Temperature and 33 and Green Pressue lights do not come on 2 Defective thermostat Won t Heat Detailed Trouble Shooting Chart page 8 3 Defective lights Exploded Parts Sheet page 30 4 Thermostat must be turned to Bar B Q position 5 Quick Check for Functions amp Controls c Power and temperature 1 Defective wiring Wiring diagram pages 31 32 lights Red and Amber and 33 comes on but Green 2 Defective Pressure Switch Won t Heat Detailed pressure light does not Trouble Shooting Chart come on 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 Function checks for Power Relay Charring Element and Main Elements A Actions and Checks Caution These checks should
41. orrectly to this point make the following test Pressure checks for leaks check for solenoid functioning calibration checks for pressure switch and time switch and addition check for main element 4 1 Remove the meat rack assembly or food basket and charring 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 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 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 Pressure starts to rise but does not get over 5 psi Green light will not go out at 12 psi Pressure will not release at 141 2 psi POSSIBLE TROUBLES 1 Leak 2 Defective Gauge 3 Defective Ejector release or safety valve 4 Defective Drain Valve 1 See 1
42. ove obstruction or replace solenoid D Check large exhaust port hole and adapter located inside cooker above and to the left of the charring element cavity If it is obstructed remove obstruction or replace hose and or adapter 16 Detailed Trouble Shooting Chart TROUBLE PRESSURE BLEED OFF TOO SLOW AT end of cooking cycle This happens either or during cooking cycle when Solenoid opens to relieve excess pressure Some times green light wiil also come on TROUBLE X TIMER SWITCH POINTER WON T MOVE CHECK OR ADJUST FOR FURTHER INFORMATION SEE A Blow though solenoid to be sure it is not obstruct How to Repair Solenoid ed if it is repair replace solenoid valve Valve page 25 or How to Replace Solenoid Disconnect exhaust hose from bottom of solenoid page 26 exhaust valve Blow through it to be sure it is not obstructed If it is remove obstruction or replace hose 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 CHECK OR ADJUST FOR FURTHER INFORMATION SEE A Plug power cord into outlet with correct voltage Rotate timer switch through positio
43. res from timer motor on timer switch from terminal strip on TB 1 and TB 5 Remove timer switch from back control box To Install new timer switch 1 Reconnect brown wires from timer motor to TB 1 and 5 on terminal block Replace black wire to top spade terminal on timer switch and orange on bottom spade ter minal on timer switch Push timer switch through the back of the face plate such that the shaft goes through the hole in the face plate Secure timer switch with two 4 40 screws to the face plate Place on timer switch knob Be sure that pointer marker on knob matches with zero when timer switch is In the Off position If it does not ad just by removing timer switch knob Loosen two 4 40 screws timer switch clockwise counterclockwise to align pointer with zero mark on face plate Check timer switch by plugging in power cord into power receptacle Then tum timer switch to 2 hour position and see if red light comes on Time timer switch with a watch for 5 min utes and see if pointer moves one mark coun terclockwise In 5 minutes If it does replace back panel HOW THERMOSTAT Pt 1002 See Figure 7 To remove old thermostat 4 Remove front knob by pulling off shaft Remove two 6 32 screws attaching thermostat to front panel 3 Remove back panel from console as outlined on this page How To R
44. ssemble solenoid see Figure 16 page 27 and follow Instructions below 1 nuts item 16 shown 2 gt Unscrew four 8 32 screws Item No 3 from Remove screws coil housing Item No 6 compression ring Item No 10 and activator guide No 12 Then remove 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 is stopped up If it is must be cleaned Do not use old seal The reason for this is once the valve has been in operation the Tefion seal tends to make a permanent set 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 buying a new valve If the coil is good it is not necessary to disas semble the coil housing To determine whether the coil is good measure the continuity be tween the two black leads coming out of the front of the coil housing with a digital ter It should read about 810 ohms itreads infinite ohms the coil is bad Replace it by proceeding to Paragraph 4 below If the coll is good skip Paragraph 4 and proceed to re assembling solenoid To the coil remove the retainer clip No 5 You may then remove the two ends and slip the old co
45. t then tighten three more turns with a 9 16 wrench Then reconnect 6 hose to fitting Replace 6 hose in right side of solenoid hand tight and then tighten three more turns with a 9 16 wrench Mount new solenoid valve on mounting bracket with 8 32 nuts Reconnect one lead slip on terminal to spade terminal on pressure switch No 2 right pres sure switch See Figure 9 page 22 Reconnect second lead fork terminal to screw terminal on TB 5 on terminal strip Reconnect hose to muffler coupling 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 14 1 2 psi solenoid should exhaust al lowing pressure to drop to approximately 13 1 2 psi and then stop exhausting If it needs ad justing see How to Adjust Pressure Switch on page 20 ADAPTER STRAIGHT LG NO 1106 HOW REPAIR SOLENOID VALVE USE TEFLON SEAL REPAIR KIT PART NO 1013 The solenoid is a very expensive part Many times it can be repaired at a much lesser cost than buy ing a new solenoid The repairs consist of replac ing the coil if it is burnt out or most generaly re placing the seal with a Teflon Seal Kit Pt 1013 Itis very important that the solenoid be reassembled correctly or it will not work when put back together To disa
46. 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 Name plate on back of the position Voltage at outlet of cover of Bar B Q Boss should be same as voltage specified on name plate 5 If not have electrician to correct B Make sure unit is disconnected from outlet How to Remove Back Remove back cover check all wire connections Panel page 20 and for loose or burnt connections Plug into outlet Wiring Diagram on and measure voltage across terminal 1 and pages 30 31 and 32 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 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 5 It should show Wiring Diagram on 208 to 240 VAC 5 If not replace white wire pages 30 31 and 32 from R 2 to TB 5 TIMER SWITCH Check time switch as follows 1 Turn timer sw
47. ty tends to leak slightly sometimas it can be stopped by slight pressure with your finger If it continues to leak replace D SEAL Check O ring for cracks or breaks Check O ring and the surface where it seats on the pot ring Both should be free of foreign matter such as hickory shavings prep mix or sauce The pot ring should also be free of nicks and scars PLUMBING Check all connections and pipe fitting in panel for leaks Check manifold connections on cooker body and around drain valve for leaks preferably with air pressure and using soap suds Tighten any loose fittings Replace drain if it leaks F VOLTAGE AT SOLENOID Check voltage How to Replace across terminal with black wire on right pressure Solenoid page 25 switch No 2 and 5 208 to 240 VAC 5 should appear If it does and solenoid will not How to Adjust close replace solenoid If 208 to 240 5 Pressure Switch does not appear at these terminals with power page 22 on check A through D of Il Won t Heat Detailed Trouble Shooting Chart If this checks How to Replace out then check voltage between terminal with Pressure Switch black wire on right pressure switch No 2 and page 22 TB 5 208 to 240 VAC 5 should appear not check adjustment of right Pressure Switch No 2 If pressure switch will not adjust replace pressure switch 12 Detailed Trouble Shootin
48. usses 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 ground or an open circuit In either event the element must be replaced each model the four elements same wattage In the BB each element is rated at 1540 watts at 240V in the BC and BCD each element is 1650 watts at 240V To replace the element see Figure 17 on page _ 29 and follow Instructions below 1 2 Remove four 10 24 truss head screws from red skirt cover and remove Remove 3 8 nut which fasten the drain valve handle adapter to the drain valve drain valve handie and adapter forward Remove bottom control panel assembly by remov Ing four 10 sheet metal screws Remove element end cap by removing four 10 sheet metal screws Remove nine 10 24 truss head screws which fas ten the top to the bottom cabinet assembly and re move bottom cabinet assembly Remove insulation clamp band by removing three 10 24 nuts holding the insulation clamp band to the top Then remove two 1 4 20 bolts from the front 28 10 11 12 13 14 15 16 17 18 19 20 21 of the clamp
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