BB ServiceManual

7/27/2019 BB ServiceManual

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Description of Models This service manual is written for models BB, BC, andqeD series. There are two models for each series.r example, in the BB series, there are models BB71d BB73. The only difference between the two Is thephase. On all models, the model designated '71" is asingle phase unit and the model designated ,3 " s a 3phase unit.Al l models can be changed in the field to either 20SVAC or 240 VAC. If the voltage is not specified whenordered, the unit will be wired for 208 VAC at the factory. It may be changed to 240 VAC by disconnectingthe top element. A single phase unit may be changedto 3 phase with a change of cord and relay. This maybe ordered as a modiflcatlon kit (see page 24).The BB unit is the smallest model. It is easily identifiable 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 knobson top. It has an inside pot diameter of 14 SIS" 1.0The BCD is the largest size. The BCD model is basically a double BC or two BC units put together in a singlecabinet. Although there is a single power source onthe BCD model, the controls mounted behind the pressure pot operate that particular pot. This means thaeach set of controls for each pot operates Independentlyof each other. This gives fleXIbility in loading and timing. It also means you won't be out of the barbecuebusiness if one side happens to malfunction. The otherside still should work Independently of that side.As far as service and repairs are concerned, all the models have the same circuitry, and operate the same.Therefore, the service will be substantially the same onall three models. The only difference in the models areSize and wattage. These difference will be pointed outin the service manual.

BB BC BCD

Description of Operation The Smokaroma barbequer combines the modem scientific method of pressure baking with pressure smoking to get that "old-fashion- hickory smoke flavor. Itdoes this economically, automatically. and in a fractionof the time to prepare barbeQue by ordinary methods.In operation as a barbequer, a small amount of hickoryis placed in the smoke generator cup. Meats or foodsto be cooked are prepared according to the recipes andthen either placed in racks which stack one on top ofthe other, food basket. or hung from spits on the meatrack. The capacity of each rack or food basket shelf isapproximately Sibs. of meat. The meat rack spits willaccommodate approximately 30 to 45 Ibs. of meat. Afte r the cooker is loaded with the desired amounts offood to be cooked, the lid Is placed thereon such thatthe two "L shaped slots are aligned with their respective 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 remainingClamp 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 aresnug.

Before heat is applied, the ejector or pressure relief valveshould be placed in the closed (horizontal) position. Thedrain valve should also be closed. It is not necessary ordesirable to release the air within the cooker.The heat is applied when the timer is set. This causesthe unit to build pressure. The wood then chars andcreates smoke, which being under pressure, is forcedall 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 psias heat Is automatically applied and removed. The pressure and temperature are automatically regulated. Apressure solenoid valve will release a small amount ofsteam should the pressure start to build over 15 psi.The ejector or pressure relief valve is open when thestem is erected in a vertical position and closed when itis in a horizontal position. There is a safety pressurerelief valve which will release the pressure if it exceeds16 to 17 psi.At the end of the cooking cycle, the pressure will beautomatically released. When the pressure gauge indicates zero pressure, the ejector valve should beplaced in the vertical (open) position to insure completeexhaust. The cooker may be opened and the cookedfood may then be removed.

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SmokaromaPreventive MaintenanceSuggestions DAILY1. At the end of each day, completely clean interior of the Bar-B-Q Boss. Do not fill with water

above bottom of smoke generator. You only "CLEANLINESSneed to pour 1 quart of water on the bottom.Add detergent (such as "Dawn" soap). Scourgood with a Scotch Brite maroon pad. Drainwater and dry thoroughly. It is not necessary ISto scour a/l the smoke stain off the cooker. It isonly necessary to scour grease and burnt crustof food off the walls, bottom and underside oftop. 90%2. Clean meat rack or food basket in sink.3. Wipe underside of lid, O-ring, and cooker potring with a damp dish cloth to clean of dirt and

debris. OFWEEKLY1. After cleaning machine, squeeze soap solutionthrough top port hole until it runs out port hole

in cooker. MAINTENANCE". Flush cooker exhaust system by placing 2quarts of water into cooker. (Add 1/4 cup soapsolution. "Dawn" is excellent.) Run up to pressure and allow cooker to "pop off' for 25 minutes. MONTHLY3. Turn off cooker and exhaust pressure. Removewater and dry cooker. 1. Observe pressure cut of f point. Green lig4. Lubricate knobs and bolt threads, underside should "cut off" at 12 psi. If not, see servof knobs, and top of lid where knobs turn. manual (page 22) for adjustment.

2. Observe pressure exhaust point. Exhaushould occur at between 14 to 15 psI. If nsee service manual (page 22) for adjustmen3. Observe timer cut off point. Dial should poto "Zero" at cut off point. If not, remove dial knand adjust.4. Observe gauge to see if it remains in calibtion, especially after abuse (for example, seethe gauge leaks, or if the dial is bent, etc.)not in calibration, replace the gauge.5. Tighten any loose nuts, bolts, or screws.There isa copper "Chore Boy" filter located Insidethe exhaust port. The exhaust port is located on 6. If ejector valve leaks, replace it.the left inside of the cooker, just to the left of the 1. Do not tamper with safety valve. If it leaks, charring element housing, if looking from the front place it.of the machine. The purpose of this filter Is to pre 8. Examine units for any broken, missing, or dvent food particles from entering your exhaust sys teriorated parts. Replace immediately; do ntem and clogging the lines. You should not oper operate in a defective condition.ate the machine without the filter in place. Changethe filter according to No.9 of "Monthly Mainte 9. Change "Chore Boy" filter at least once p

nance Suggestions". month and more often with heavy usage.-2

Figure 1

COPPER FILTER' C H ~ BOY'PT. NO . 1790


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Controls & Functions

. Figure 21. 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 applied to machine. 3. Thermostat'ovides automatic "Hold" control. Provides overeat prevention control. When set at IIBar S.aposition. thermostat will cut out .at a bottom temperature of 5500 F. When this happens. both thetemperature neon light (amber) and the green neonlight will go off, or if in "Cold Smoke" mode theamber and white light will go off. When the temperature drops below 5500 F, the thermostat willautomatically cut back on.4. Amber Neon Indicator Light (Temperature)Indicated voltage is being applied through thermostat to heating elements.5. "Cold Smoke" SwitchProvides "Cold Smoke"- "Hot Smoke" mode. Inthe "Qtr or down position, the unit is in the "ColdSmoke mode; only the Charring Element will heat.The white neon light will come on (with amber andred) when the timer is set to "On" and the thermostat is set to Bar-S-O.In the "On" or up position, the unit is in the "HotSmoke" mode. The main elements will provide"eat along with the Charring Element. The greenjon light will be on (with amber and red) whene timer is set to "On" and the thermostat is set toBar-B-O. However, the green light will cycle offwhen approximately 12 psi is reached and on whenpressure drops below 10 psi.

6. Green Neon Indicator Ught (Pressure) Indicates voltage is applied through pressureswitch to heating elements. Should go out at 1psi. Green light will not light in "Cold Smoke" mode7. White Neon Indicator Light (Cold Smoke) Indicates when "Cold Smoke" switch is in the "ColSmoke" mode. 8. Ejector Valve Provides manual valve for closing to build pressure and opening to relieve pressure. 9. Safety Valve Provides valve for relieving pressure should it exceed 17 psi. Resets at 15 psi. 10. Pressure Gauge Indicates pressure (psi). After initial pressure ibuilt up, it normally operates between 12 .and 15psi (indicated by green area). 11. Drain Pan Use In cleaning cooker. It Is located beneath thecooker directly beneath the drain valve. Pancatches drippings out of cooker pot when openingdrain valve. . 12. Charring Cup Container which holds wood for charring during thesmoking process. 13. Charring Element Provides heat source of 230 watts at 240 volts forcharring wood. 14. Lid Rack Used to hold the top lid when not in use. It is located on side of cooker cabinet. 15. Muffler Designed to condense some moisture being re-leased from the machine and prevent splatteringon the wall. 16. Drain Valve and Handle Provides for cleaning when opened. Should beclosed during the cooking operation. Valve isopened when handle is rotated counterclockwiseto the down or vertical position. 17. O-Ring Provides pressure seal when lid is clamped inplace.

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Controls & Functions

Figure 3

18. Power Relay Provides power to the main elements when energized by control c i r c u i t ~ The control circuit consists of timer switch. thermostat and Pressure 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 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. 20. Exhaust Solenoid Provides valve to exhaust steam automatically

at end of cooking cycle and to control presat below 15 psi by exhausting intermittentlying cooking cycle. The exhaust solenoid Is trolled by the Timer Switch and Pressure SwNO.2.21. Terminal Strip (TB-1 thru 5) Provides junction for connecting wires. 22. Low Side (Left) Pressure Switch (No.Opens control circuit at 12 psi to de-enerPower Relay thereby removing heat. Close11 psi on pressure drop to energize power rthe reby adding heat.23. High Side (Right) Pressure Switch (NOpens solenoid at approximately 14 1/2 pcontrol pressure at below 15 psi. Closes aproximately 13 1/2 psi on pressure drop.-4


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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 functioninrrectly. It ma.lnly consists of visual checks and checks by touch. It is divided into three parts: "FunctioIndicator Lights . . . ", "Function checks for Power Relay . . ", and "Function checks for leaks. . .

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 whencold smoke switch is in the up position) should light and then go off when the pointer on thetime switch reaches "0" time.C. Possible Troubles - If these things do not happen, it may indicate one or more of the followingtroubles: .

SYMPTOMS POSSIBLE TROUBLES TO REPAIR SEE:. No indicator lights come on. 1. Assuming correctvoltage is "I. Won't Heat, 9, Detailedavailable at the outlet, defective Trouble Shooting Charf' ,wiring in power cord. page 8 and "Wiring Diagram",pages 31 , 32, and 33.

2. Defective wiring in control box. "I. Won't Heat, C, DetailedTrouble Shooting Chart",page 8 and "WiringDiagram", pages 31,32 and 33

3. Defective timer switch "I. Won't Heat, D, DetailedTrouble Shooting Chart",page 8 and "HowReplace Timer Switch",page 20.4. Defective lights. Exploded Parts Sheet, page 30

Power light comes on 1. Defective wiring. Wiring diagram pages 31, 32,but Amber (Temperature) and 33.and Green (PresslJe)lights do not come on.2. Defective thermostat. "I. Won't Heat, E, DetailedTrouble Shooting Chart",page 8.

3. Defective lights Exploded Parts Sheet, page 304. Thermostat must be turned to

8ar-8-Q position. -5


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Quick Check for Functions & Controc. Power and temperaturelights (Red and Amber)comes on but Greenpressure) light does notcome on.

1. Defective wiring.2. Defective Pressure Switch.

Wiring diagram. pa.ges 31and 33."I. Won't Heat DetailedTrouble Shooting Chart",page 8.3. Defective Lights. Exploded Parts Sheet, pag4. 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 shoumade 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 fromcold start.1. Rotate thermostat to the "BAR-B-Q" position and then rotate timer switch to "2" hours onthe 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 thetouch 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 maytake 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 followingproblems. .

SYMPTOMS POSSIBLE TROUBLES TO REPAIR SEE:e. Charring Element does not 1. Defective wiring. For all troubles listed herebecome warm. "IV .Won't Create Smoke,. Detailed Trouble ShootingChart'", page 13.

2. Defective Thermostat.3. Defective Charring Element

f. Side of cooker does not 1. Defective wiring. For all troubles listed herewarm. "I. Won't Heat, Detailed TroShooting Chart", page 8.2. Defective Power Relay.3. Defective Main Elements. (Note: This unit has fourseparate elements. Theref4. Cold Smoke Switch must be it's rare that all elements win "UP" position and green light burn out at once unless anis "on". voltage has been applied. likely the wires from the p

relay are defective.6-


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F. Assuming that al l controls or parts are functioning correctly to this point, make the following tesIII. Pressure checks fo r leaks, check fo r solenoid functioning, calibration checks fo r pressure switcand 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 pressure is rising.4. The solenoid should exhaust when the pOinter of the gauge is between 14 and 15 psi whenpressure is rising.

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

a.SYMPTOMS

Pressure does not start torise at all after 15 minutes.

POSSIBLE TROUBLES1. Leak2. Defective Gauge

TO REPAIR SEE: ."III. Heats But Won't BuildPressure, Detailed TroubleShooting Chart", page 12.

3. Defective Ejector, release, orsafety valve4. Defective Drain Valve

b. Pressure starts to rise 1. See A 1, A2, and A3 above. "". D. Heats Only Warm,but does not get over 5 psi. Detailed Trouble Shooting2. One or more Main Elements Chart", page 11.is defective.

c. Green light will not go out 1. Pressure setting is too high "How to Adjust Pressureat 12 psi. Switch", page 22.d. Pressure will not release 1. Pressure Switch setting is too "How to Adjust Pressureat 141/2 psi. high or low. Switch", page 22.

2. Defective solenoid3. Pressure line stopped up. "VII. Won't Exhaust, DetailedTrouble Shooting Chart",

page 16.-7


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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 furtherneed to do to fix it under "For Information See". We tried to list the "Trouble" just as the customer waexperience or say it. The most prevalent trouble, "Won't Hear is listed first. To repair, find the descripwhich is mostly closely associated with the problem and proceed step by step down the "Check or Adjlist. When the problem is isolated to a part, see the reference listed under "For Further Information See"this solves the problem, you may then test the unit according to the "Quick Check" to make sure everythis 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 concircuits (208 to 240V AC, single phase) are the same regardless of the voltage or phase, the trouble shing will be the same for it. Where the procedure differs it will be marked clearly with a phrase "FoPhase".

Detailed Trouble Shooting Chart TROUBLE CHECK OR ADJUST FOR FURTHER

INFORMATION SEE1. WON'T HEAT A. VOLTAGE - (Thermostat should be rotated tothe "SAR-S-O" position). Voltage at outletshould be same as voltage specified on nameplate 5%. If not, have electrician to correct.

B. Make sure unit is disconnected from outlet.Remove back cover, check all wire connectionsfor loose or burnt connections. Plug into outletand measure voltage across terminal R1 andR-2 of power relay. Voltage should be the sameas 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 terminalsR-1 and R-2, across R-1 and R-3, and acrossR-2 and R-3. Voltage should be the same as thatspecified by the name plate 5%.

C. Check voltage R-1 and TB-S. It should show208 to 240 VAC 5%. If not, replace white wirefrom R-2 to TB-5.D. TIMER SWITCH - Check time switch as follows:1. Turn timer switch to "1" hour position.

2. Connect voltmeter across TB-1 and TB-5 onterminal strip. Voltmeter should read 208 to240 VAC 5%. If it does, proceed to "En.3. If it does not, check wiring up to this pointby removing black wire to timer switch, fromthe timer switch terminal. Connect voltmeteracross the end of the black wire and at relayR-2 terminal. Voltmeter should read 208 to

240 VAC 5%. If It does not, replace black wire.-8

Name plate on back ofof cover of 8ar-8-Q Bo

"How to Remove BackPanel", page 20 and "Wiring Diagram" on pages 30, 31, and 32.

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

. "Wiring Diagram" onpages 30, 31, and 32.

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


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4. Turn timer switch to the "On" position andmeasure the voltage from the timer switchterminal where the orange wire is connectedand TB-S. The voltmeter should read 208 to240 VAC 5%. If it does not, replace the timerswitch. If it does, connect voltmeter acrossTB-1 and TB-5 on terminal strip. Voltmetershould read 208 to 240 V AC 5%. If it doesnot, replace orange wire. If it does, proceedto "E" below.E. THERMOSTAT - The thermostat should be inthe "BAR-B-a- position. Check the voltagebetween TB-2 and TB-S. The meter should show208 to 240 VAC 5%. If it does not, check thevoltage between the thermostat terminal wherethe purple wire connects and TB-5. Voltmetershould 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 betweenthe thermostat terminal on which the black andwhite striped wire is connected and TB-S. If it

does not, replace the thermostat. If 208 to 240VAC 5% appears, then proceed to "P.F. PRESSURE SWITCH NO.1 - Check voltagewith voltmeter between Pressure Switch No.1terminal (left pressure switch) on which thegreen wire appears and TB-5. Voltmeter shouldread 208 to 240 VAC 5%. If it does not, replacethe green wire. If it does, check the voltagebetween the Pressure Switch No.1 terminal onwhich the blue wire appears and TB-5; 208 to 240

VAC 5% showd appear. If it does not, adjust thepressure switch. If pressure will not adjust, replacepressure switch. If the voltmeter does read 208to 240 VAC 5% proceed to "Gil below and check.G. POWER RELAY - Check the voltage with a voltmeter between terminals R-4 and R-5 on thepower relay coil. Voltmeter should read 208 to240 VAC 5%. If it does, and the relay is notenergized, replace the relay. If the voltmeterdoes not read 208 to 240 VAC S% check thevoltage between R-4 and TB-5. Voltmeter shouldread 208 to 240 VAC 5%. If it does not, replacethe blue wire to the coil. If it does read 208 to240 VAC 5%, replace the white wire from thecoil to TB-S. If the relay is energized and elementsdo not heat, proceed to "H- and check.H. MAIN ELEMENTS - Remove bottom control panelcover to expose the element ends. There arefour (4) elements per cooking unit. Three (3) areused for 240/415 volts operation and four (4) areused for 208-220/380 volts operation. Check thevoltage between R-6 and R-7 of the power relaywith the relay energized. The voltmeter shouldread 208 to 240 VAC 5%.

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"How to Replace TimerSwitch", on page 20.

"How to ReplaceThermostat", page 21.See "Wiring Diagram",pages 30, 31 and 32.

'Wiring Diagram- onpages 30, 31 and 32.

"How to Adjust PressureSwitch", page 22."How to Replace PressureSwitch, page 22."Wiring Diagram- onpages 30, 31 and 32, andHow to Replace PowerRelaY'. page 23.

"How to Remove BackPanel and Bottom ControPanel Cover". page 20.Wiring Diagram, pages30,31 and 32.


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Detailed Trouble Shooting Chart For 3 Phase: With the relay energized, check thevoltage between R-6 and R-7, between R-6 and R-aand between R-7 and R-B. Voltage should be thesame, in each case, as that specified by the nameplate 5%. .Single Phase Cont.: Check the voltage at the "How to Replace Heaelement terminals where the leads are connected. Element", page 29.The voltmeter should read 20B to 240 VAC 5%.If it does not, check continuity of the lead wires byconnecting 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 itdoes not, replace the lead wire on the left side.Reverse this process by checking the voltage betweenterminal R-7 on the power relay and the elementterminal on the right side of the elements. Thevoltmeter should read line voltage 5%. If it does not,replace the lead on the right side.If the voltmeter reads line voltages across the terminalof the elements and anyone does not heat, remove allconnections on the elements and check the resistancewith ohmmeter of each element. The resistance shouldread 35 ohms 5% for the BC and BCD and 37 5%ohms for the BB. If the ohmmeter indicates differentlythan these values, replace the element or elements.For 3 Phase: Check the voltage at the element terminalswhere each of the three leads are connected. That is,check between lead one (1) and lead two (2), lead one (1and lead three (3), and 'lead two (2) and three (3). Ineach case, the voltmeter should read line voltage 5%. Ifit does not, check continuity of the lead wire by connectingone voltmeter lead to R-6 and any of the other twocorresponding lead terminal at the element. For example,if your voltmeter lead is on R-6 then the other lead shouldbe on the lead terminal end at the element of lead two (2).The voltmeter should read line voltage. If it does not, replace lead two (2). Repeat this process for R-7 checkingthe voltage at the end of lead 3 at the element terminal.Also for R-8, checking the voltage at the end of leadone (1) at the element terminal. You may also check con

tinuity of the lead wires with an ohmmeter. Be sure the unitis unplugged and voltage is removed. Check the continuityby measuring between R-6 and the end of the lead in at theelement terminal. If it does not have cont.inuity, replace thelead. Repeat this process for R-7 and R-8.It lhe voPbrrem reads line voltage across the terminals ofany of the elementS and any one element does not heat, remove all connections on the element and check the resistance with the ohmmeter of each element. The resistanceshould read 35 ohms 5% for the Be and the BCD, and37 5% ohms for the BB. If the ohmmeter indicates differently then these values, replace the element or elements.-10


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Detailed Trouble Shooting Chart CHECK OR ADJUST FOR FURTHER

INFORMATION SEE

n. HEATS ONLYWARM ANDPRESSUREBUILDS UPEXCEEDINGLYSLOW

A. VOLTAGE - Check line voltage and be surethat the voltage [s same as specified onnameplate 5%. If it Is, check and see if 208to 240 VAC 5% Is applied to the L1 and L2wires in power coret Green wire should begrounded. Sometimes with a three wirepower cord, a lower voltage is applied to thecooker through error. If this Is the case,correct plug or receptacle such that thecorrect voltage is applied, to L1 and L2wires in power cord.For 3 Phase: Une voltage should appearbetween l1 and L2, L1 and l3. and L2 andLa.

B. Check amperage with an "Amp robe typemeter by encircling one lead to mainelements. It should read not less than 20amperes (See Wiring Diagram page 30 foractual 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 current reading should notbe less than 5 amperes but not more than11 ampheres. (See WIring Diagrams, pages31 and 32) for actual current on l1 , L2, and L3.

C. MAIN ELEMENTS - With the timer switchOn" and the thermostat rotated to "Bar-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 Trouble Shooting Chart" then correctdefective parts. If the 208 to 240 VAC 5%appears across terminals of main elementsproceed to "H "I. Won't Heat, Detailed TroubleShooting Chart".-11

Wiring Diagram, page30, 31 and 32.

Wiring Diagram. page30. 31 and 32.

"How to Replace MainElement", page 29.


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Detailed Trouble Shooting Chart TROUBLE CHECK OR ADJUST FOR FURTHERINFORMATION SE

m. HEATS BUTWON'T BUrLDPRESSUREA. GAUGE - Check for leaks around gaugeconnections. If loose. tighten. Check gaugeto see if pointer is unobstructed. If defective,replace gauge.

B. EJECTOR VALVE - When stem is down. ejectorvalve should be closed and pressure tight. Ifthe ejector valve leaks. replace.C. SAFETY VALVE - Safety valve should functionat 17 1 psI. It will then reset Itself, at app roximately 15 pst. If the safety tends to leak slightly,sometimes It can be stopped by slight pressurewith your finger. If it continues to leak, replace.

D. SEAL - Check O-ring for cracks or breaks.Ch eck O-ring and the surface where It seats onthe pot ring. Both should be free of fo reignmatter, suc h as. hickory shavings, pre p mix orsauce . The pot ring should also be free ofnicks and scars.E. PLUM BING - Check aJl connections and pipefitting In panel for leaks. Check manifoldco nnections on cooker body, and around drainvalve for leaks (preferably with air pressure andusing soap suds). Tighten any loose fittings.Rep lace drain valve if it leaks.F. VOLTAG E AT SOLENOID - Ch eck vo ltage

acro ss term inal with black wire on right pressureswitch (No.2) and T8-5, 208 to 240 VAC 5%should appear. If it does and solenoid will notclose, replace solenoid. If 208 to 240 VAC 5%does not appea r at these terminals with poweron, check "A- through -0- of "I. Won't Heat,Detailed Trouble Shooting Chart". If this checksout, then, check voltage between terminal withblack wire on right pressure switch (No.2) andTB-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

"How to ReplaceSolenold-, page 25."H ow to Ad justPressure Switch-.page 22."How to ReplacePressure Switch-,page 22.


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Detailed Trouble Shooting Chart ' lOUBLE CHECK OR ADJUST FOR FURTHERINFORMATION SEE:V. WON'TCREATESMOKE

A. VOLTAGE - With time switch set at "1 hour andthermostat at "Bar-B-Q" position, check voltage across TB-2 and TB-S. LIne voltageshould appear. If not, voltage should bechecked as specified In "A" through "E underIII. Won't Hear trouble.

B. CHARRING ELEMENT - If 208 to 240 VAC 5% appears across T8-2 and T8-5, thecharring element should heat. If it does not,check for loose terminals. If none are found.replace charring element. AHemate: Checkthe resistance of the charring element with anohmmeter. It should read 250 ohms 10%.If it does not, replace the charring element.

"How to ReplaceCharring Element",page 21.

CHECK OR ADJUST FOR FURTHERINFORMATION SEE:ERHEATS A. Check for leaks. If cooker is leaking, Itcannot get up to cutoff pressure (12 psifor left pressure switch No.1) to open

solenoid and remove heat, and cookerwill overheat.B. LEFT PRESSURE SWITCH (1) - Pressureswitch should cut off at 12 psI. If It does not,adjust pressure switch to cut off at thispressure. If pressure switch will not adjust,replace.C. RIGHT PRESSURE SWITCH (2) - Pressureswitch should open.solenold at 14 1/2 psi andrelease pressure to approximately 13 112 psi.

If it does not, adjust pressure to open at141/2 psi. If pressure switch will not adjust,replace.D. THERMOSTAT - The thermostat is designedto prevent overheating, and possible damageto unit. It Is designed to cut off at a temperatureof 5500 F at point on which the thermostat bulbis mounted. Rotate thermostat knob slowlytoward "oW. Thermostat should click off .somewhere between "hold" and "orr posItion atapproximately the 2:00 o'clock position.

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"How to Adjust PressureSwitch", page 22."How to Replace PressureSwitch, page 22."How to Adjust PressureSwitch", page 22."How to Replace PressureSwitch", page 22.

"How to ReplaceThermostar, page 21.


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Detailed Trouble Shooting Chart TROUBLE

TROUBLE

VI. PRESSUREBUILDS UPHIGH

CHECK OR ADJUST FOR FURTHERINFORMATION SEE. MAIN ELEMENTS - Check element connection Rewire Connectionsconfiguration to see if they are wired for the ~ r i n g 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 highvoltage operation (240/415 volts). three (3)elements are used. If four (4) elements areused on high voltage operation, the unit willoverheat. 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 Pow. open when no voltage is applied. You should be RelaY', page 23. able to move the contactor from the nonnally 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. .

CHECK OR ADJUST FOR FURTHERINFORMATION SEEA. CHECKING PRESSURE LINES AND CONNECTORS1. Check large exhaust port hole, and adapter

located inside cooker above and to the left of thecharring element cavity. Remove back panel. Besure hose and adapter are not stopped up bydisconnecting hose from solenoid and blowingthrough hose. If there is any obstruction, replacehose andlor adapter.2. Remove Muffler and blow .through it to be sureit is not stopped up. Clean to remove anyobstruction.3. Check pressure switch port hole located on back

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Detailed Trouble Shooting Chart of charring element housing. Be sure it is notstopped up by disconnecting hose from pressureswitches manifold and blowing th rough hose . Ifthere is any obstruction, replace hose and/oradapter.

B. LEFT PRESSURE SWITCH (1) - Observepressure Indicated on gauge at which pressureIndicator light (green) cuts off. This po int shouldbe at 12 pSi. If not, adjust pressure switchto open at this point If pressure switch will notadjust, replace.

C. RIGHT PRESSURE SWITCH (2) - Pressureswitch should open solenoid at 14112 psI andrelease pressure to approximately 131/2 psI.If it does not, adjust pressure switch to open at14112 psI. If pressure switch will not adjust,replace.

D. POWER RELAY - Power Relay should benormally open when no voltage Is applied. Youshould be able to move the contactor from thenormally closed position with your fingers (makesure power cord Is removed before try ing this).If the contacts are welded in the normally closedposition, replace relay. If contact points are badlypitted, replace power relay.

-How to Adjust PressureSwitch-, page 22."How to ReplacePressure Switch-,page 22.

-How to AdjustPressure Swltch-,page 22."How to ReplacePressure Switch-,page 22 .

"How to Replace PowerRelay" page 23.

TROUBLE CHECK OR ADJUST FOR FURTHERINFORMATION SEE:

vn. PRESSURECUTOFFPOINTVARIESORCHANGESAFTERADJUSTING

A. Tighten Micro-Switch attachment screws on eachpressure switch.

B. LEFT PRESSURE SWITCH (1) - Observepressure Indicated on gauge at which greenindicator light cuts off. This point shouldbe at 12 psi. If not, adjust pressure switchopen at this point. If pressure switch will notadjust, replace. -15

"How to Adjust PressureSwitch", page 22.-How to ReplacePressure Swltch-,page 22.


17/38

Detailed Trouble Shooting Chart

TROUBLE

VllI. WON'T. EXHAUST

C. RIGHT PRESSURE SWITCH (2) - Pressure "How to Adjustswitch should open solenoid at 14 1/2 psi and Pressure 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 ReplaceIf pressure switch will not adjust, replace. Pressure Switch", page

D. CHECKING PRESSURE LINES AND CONNECTORS1. Check large exhaust port hole, and adapterlocated inside cooker above and to the left of thecharring element cavitiy. Remove back panel.Be sure hose and adapter are not stopped up bydisconnecting hose from solenoid and blowingthrough hose. If there is any obstruction, replacehose and/or adapter.2. Remove Muffler and blow through it to be sure itis not stopped up. Clean to remove any obstruction.3. Check pressure switch port hole located on backof charring element housing. Be sure it Is notstopped up by disconnecting hose from pressureswitches manifold and blowing through hose. Ifthere is any obstruction, replace hose andlor adapter.

CHECK OR ADJUST FOR FURTHERINFORMATION SEE

A. Remove muffler and blow through it to be sure it is "How to Reoair Solennot stopped up. Crean it to remove any obstruction. ValVe-; page 2'6 or"How to Replace Solenpage 25.B. EXHAUST HOSE - Disconnect exhaust hose

from solenoid valve to muffler. Blow through it tobe sure that It Is not obstructed. If it is, removeobstruction or replace hose.C. Remove hose from solenoid bottom. Blowthrough solenoid to be sure it is not obstructed.It it is, remove obstruction or replace solenoid.D. Check large exhaust port hole and adapter locatedinside cooker above and to the left of the charringelement cavity. If it is obstructed, remove obstruction orreplace hose and/or adapter.

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Detailed Trouble Shooting Chart TROUBLE CHECK OR ADJUST FOR FURTHERINFORMATION SEE:

IX. PRESSUREBLEED OFFTOO SLOW ATend of cookingcyc le. (ThIshappens eitheror during cookingcycle, whenSolenoid opensto relieve excesspressure. Sometimes green lightwill also come on.

A. Blow though solenoid to be sure it is not obstructed, if it is, repair or replace solenoid valve.

B. Disconnect exhaust hose from bottom of solenoidexhaust valve. Blow through it to be sure it Is notobstructed. If It is, remove obstruction or replacehose.C. Disconnect solenoid exhaust hose from side ofsolenoid to muffler. Blow through it to be sure It Isnot obstructed. If it is, remove obstruction orreplace.D. Check large exhaust port hole and adapter locatedinside cooker above and to the left of the charringelement. If it is obstructed, remove obstruction orreplace hose and/or adapter.

"How to Repair SolenoidValve, page 25 or "How toReplace SolenOid",page 26.

TROUBLE CHECK OR ADJUST FOR FURTHERINFORMATION SEE:

x. TIMER SWITCHPOINTER WON1T'MOVE " -,A. Plug power cord into outlet with correct voltage.Rotate timer switch through lOON poSition and allthe way around clockwise slowly to the Zero timeposition. If timer switch is working correctly red'(power) indicator light will light and then go off atthe ZERO time division: If red light does not comeon, then proceed to C and check.B. If red light comes on and timer switch Is Incalibrat ion, tum timer switch pointer to "2" hourposition and time with watch. Timer switchpointer should move one mark clockwise in 5minutes. If pointer does not move, check to see

if timer switch motor-leads are connected to TB-1and TB-5. If they are and pointer does not move,proceed to "C".C. Check timer switch as follows:1. Tum timer switch to 1 hour position.

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Detailed Trouble Shooti 9 Chart 2. Connect voltmeter across T8-1 and TB-5 onterminal strip. Voltmeter should read 208 to240 VAC 5%. If it does replace timer switch.3. If it does not, check wiring up to this point byremoving black wire to time switch, from the

time switch term inal. Connect one lead ofvoltmeter to the end of the black wire and theother lead to relay R..2 terminal. Vo ltmetershould read 208 to 240 VAC 5%. If it doesnot, reptace wire. If the voltmeter does read208 to 240 VAC 5% at the end of the terminal,put the wire back on timer switch terminal.4. Tum timer switch to the -On- posltion andmeasure the voltage from the timer switchterminal where the orange wire Is connectedto and where the other end Is connected to TB5.Th e voltmeter shou ld read 208 to 240 VAC 5%.If It does not, replace the time switch. If itdoes, replace the orange wire and repeat -eabove.

-How to Replace TimSwitch, page 20.

-How to Replace TImSwitch, page 20.

TROUBLE CH ECK OR ADJUST FOR FURTHERINFORMATION SE

XI. CHATT.EBINONOISE INBACK WHENT1MER ISTURNED ON .

Note: Generally this conditiondescribes"aJow.voltage or Incorrect vo ltage application. The mostcommon which occurs is the application of 120Von a 240V line. The resu lting noise Is caused bythe relay and solenoid trying to -pullin but can'tbecause of insufficient voHage (both have 208 to240V colis). This problem is generally caused bythe plug or receetacle being wired Incorrectly.

A. VOLTAGE - Check line voltage and be surethat it is same voltage as that specified on nameplate 5%. If It Is, check and see If line voltageIs applied to the L1 nd L2 wires in power cord.Green wire should be grounded. Sometimes ona three wire system. one half voltage (110 to 120volts) Is applied to the cooker through error. Ifthis Is the case, correct plug or receptacle such-18

H Q W .to,Be.pJaceCbElemenf' , page 21.


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Detailed Trouble Shooting Chart that correct voltage Is applied. to black andwhite wires in power cord.

B. Check amperage with an ..Amprobelt typemeter by encircling one lead to the mainelement. It should read no less than 20amperes. If it reads less than 20 amperes,check itA" above. (See wiring diagram foractual current on L1 and L2).

Wiring Diagram.pages 30. 31 and 32.

For 3 Phase: This current reading will be less than 5 amperes but not more than 11amperes (See wiring diagram for actual current on L 1, L2, and L3.

TROUBLE CHECK OR ADJUST FOR FURTHERINFORMATION SEE:'i l l . TIMER SWITCH"OFF"BUTINDICATORLIGHTS ON

DIM ANDRELAY ANDSOLENOIDCHATTER.

Note: Generally this contion describes acharring element shorted to the ground.In thi.s case. the charring element mayormay not heat. However, It allows a voltage(maximum of 120 volts) to be applied across thelights, power relay and solenoid from the otherside of 240 volts (even though the timer Is off).The low voltage Is sufficient to alow them tolight dimly and to chatter. but it is not enough tofully 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, checkvoltage from T8-3 to TB-4, If voltage readsup to 120 volts, replace charring element.You may also check the charring element forground with an, ohmmeter. To do this, removeboth charring element leads from T8-3 andTB-4. Touch one lead to one of the Ohmmeterleads and the other Ohmmeter lead to thecooker cabinet. Then touch the other lead toone end of the Ohmmeter and the other leadto the Ohmmeter to the cooker cabinet. If eitherread zero ohms, replace charring element.

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"How to Replace CharrinElemenr, page 21.


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HO W TO REMOVE B.ACK PANELS See Figure 5

To remove back panel:1. Caution: Always rem ove plug from power outlet before removing back panel.2. Remove six 10-24 sc rews from back panel.

CCINTIIII. ...,. COIiB

" 10. tf6O. IICII

...........-PT lID. MICO'IDPT lID. IMO, " 10. 1910, Ie

FIgure 5

Removing the bottom control panel cover.If It Is necessary to check the heating elements,change the heating elements, or change the wlr,ing for different line voltage for the ma chine tooperate on, you must remove the bottom controlpanel cover. This panel may be seen after removing the back cover.1. Caution: Always rem ove plug from power outlet before removing back panel or bottom control panel cover.2. To remove the bottom control panel cover, simply remove the three (3) No.1 0 Pan Head SheetMetal Screws. Then the panel may be removed.

HO W TO REPLACE TIMER SWITCH Pt. No. 1008 50HZ Pt. No. 1012 60 HZ See Figure 6 To remove the time, switch:1. Remove timer switch knob by pulling if off shaftfrom the front.2. Remove back panel as outlined In -How to Remove Back Panel-.

3. Unsc rew two 4-40 screws from the front hing the timer switch to the face plate.4. Re move timer switch and disconn ect blackorange wires from terminals on the timer sw5. Remove brown wires from timer motor on tswitch from terminal strip on TB-1 and TB6. Remove timer switch from back control boTo lnstaJl. new timer switch: .1. Reconnect brown wires from timer mo tor to1 and TB-5 on terminal block.2. Replace black wire to top spade terminal otimer switch and orange on bottom spademinal on timer switch. '3. Push timer switch through the back of the.plate such that the shaft goes through the in the face pia_e.4. Secure timer switch with two 4-40 screws toface plate.5. Place on timer switch knob. Be sure that pomarker on knob matches with zero, when tswItch Is In the -Ofr posltion. If it does notjust by removing timer switch knob. Loosen4-40 screws. Tum timer switch clockwisecounterclockwise to align pointer wi th zero mon face plate.6. Check timer switch by plugging in power cInto powe r receptacle. Then tum timer swto "'2- . hour position and see if red light coon . l ime "'mer switch- with a watch for 5utes and see if pointer moves one mark coterclockwise 1n 5 minutes.7. If it does, replace back panel.

T Ia MOT1It LIMItoni LU I I S " - . . . 111

Figure 6

LUllSILUI HZ

Tlaa IC I!'T. 1C0. - --_..1

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---

HOW TO REPLACE THERMOSTAT Pt No. 1002 see Figure 7

To remove old thermostat:1. Remove front knob by pulling off shaft.. Remove two 6-32 screws attaching thermostat

to front panel.3. Remove back panel from console as outlinedon th is page. -How To Remove Back Panel" on

page 20.4. Remove two wires from the thermostat te rminal. Lean cooker forward until top front restson floor. .5. Remove red skirt cover.6. Loosen 10-24 screw holding thermostat bulbclamp. .7. Remove thermostat bulb.8. Remove thermostat.To Install new thermostat:1. Replace old thennostat with new thermostat.

Thread bulb and capillary tube back throughhole In control box in back of cooker and placebulb in the clamp on the bottom of cooker.2. Tighten screw and clamp bulb In place.3. Replace red skirt cover with four 10-24 screws.4. Tum cooker right side up.S; . Replace wires on thermostat terminal as perfigure 7.soAttach thermostat to front panel with two 6-3screws.7. Place thermostat knob on thermostat. Tum cold

smoke switch toward green light. Place plugin power outlet. Tum timer switch knob to "2"hour setting.8. Tum thermostat knob to -BAR-S-O" position.(Amber and green Jights should come on whenthermostat Is turned to -BAR-B-O" position.)Charring element shoutd get hot and inside ofpot should get warm.

- . .

~ Figure 7

HOW TO REPLACE 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 fromterminal strip TB-3 and T8-4.3. Remove complete charring element by unscrewing fitting with an adjustable end wrenchThis fitting is located in back of charring element housing which is in back of cooker.To Install new element:1. Place anti-seize compound or teflon tape onpipe threads of charring element housing.2. Tighten charring element into place with adjustable end wrench.3. Replace electrical connections. One lead fas

tens to TB-3 on terminal strip the other fastensto TB-4 on terminal strip. See terminal designation on wiring diagrams on pages 30. 31 and32.

4. Test by plugging power cord into power andturning on timer switch, the charring elementshould become hot to touch Immediately.

5. Replace back panel.

Figure 8

'-21- '


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HOWTO REP LACE PRESSURE SWITCH pt No. 1003 See Figure 9

To remove old pressure swUch:1. Remove back panel as outlined on page 20.2. Remove wires (2) from pressure swItch termi-nals.3. Unscrew pressure switch from manifold using

3148 open end wrench.To Install new pressure switch:1. Screw pressure switch on manifold using 314open end wrench. (See Figure 9 below)2. Set according to pressure setting In figure 10.(See -How to Adjust Pressure SWitch.)3. Replace back panel after installation is com-pleted.

--IMIQIT....... It..

Figure 9

HOW TO ADJUST PRESSURE SWITCH pt. No. 1003

See FJgure 10 Note: This procedure requires two people; onobserve gauge and one to make pressure settIt can be done with one person by using a mimounted on lid such that gauge can be seenmirror 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 "1hour.4. Let pressure build to approximately 15 Ibs.While pressure Is bu ilding, adjust the right s

pressure switch (No .2) counterclockwise aviewed from top until solenoid releases presure.5. Continue. o adjust until solenoid relieve presure at between 14 to 15 psi on the gaugeface plate (approxImately 14 1/2 psi).6. Now relieve pressure by opening ejector vauntil gauge reads approximately 10 psi. Tuknurled adjustment screw until green light gout (left pressure switch, No.1) at 12 psI.. Tpower relay will open at this point and heatremoved. Repeat this step until this settingas 12 pSi.

KNURLEWHEEL

Figure 10

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HOW TO REPLACE SINGLE PHASE POWER RELAY (Par t No. 0317) See Figure 11

To remove o ld 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 conRemove all wires from power relay terminals. trol box.3. Remove defective relay by unscrewing two 8 2. Replace all wires as shown in Figure 11 below32 screws attaching Jt to control box . Caution: "you use a DPDT relay, make sur

that the lead from relay to heating element terPOWER RB.AY minals are on the normally open relay termnals.PT NO. 0317

--"-IEL&YPT 110. 0S7(SII IaJ "HUE)

/ '-/' :: '-------SCREW. 1-32 x1/2~ . I ~ 1 92 EA.Figure 11

HOW TO REPLACE THREE PHASE' POWER RELAY(Part No. 1511) See Figura 12To 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 con2. 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 below32 screws attaching It to control box. Caution: If you use a DPOT relay, make sure

, . /~ S O t ! W . H z x l nPT NO . 1319Z!A.Figure 12

that the lead from relay to heating element ter'mlnals are on the normally open relay terminals.

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SINGLE PHASE TO THREE PHASE CONVERSION KITiPart No. 2260 and 2265)Single phase to three phase converison kits are available. They are part number 2260 for lower volta(208 - 240 volts , Delta) and part number 2265 for higher voltage (380/415. Wye). The kit consists of a powcord with cap, 3 pole relay, 2 element wires, and one flexible jumper to wire the elements in "Delta-. An exelement wire is provided In P a r t . ~ 2 2 6 5 for conversion to the higher voltage for connecting from the 'W

n e u ~ r a l to the system neutral, if required. Most U.S. three phase installations will be a lower voltage, 208240 volts (Delta). However, the cooker can be wired for a higher voltage of 415 volt CNye) operation. MIntemational installation in 3 phase will be 220 vo lts (Delta) for the lower voltage. However, the cooker cbe wired for 380 volts &lye) operation for the higher vo ltage . if you need to convert a single unit to 3 phaorder the conversion kit and co nnect the elements as follows.

LOW VOLTAGE (208 TO 240 VOLTS)"DELTA"

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

DC DD211 \Q.T CR 220 m IffJAD 240WlTIRRAD I( J ~igure 13 {l PH&}L________ ~ __________________ ~ tLOW VOLTAGE (3801415 VOLTS)

"WYE"PARTNO. 2265

Ir----------------------,I I I I I I I I I I \DE, JIIO m CHRAlD I (JAW) I Figure 14

~ - - - - - - - - - - - - - - - - - - - - - - ~-24


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HOW TO REPLACE SOLENOID VALVE(Part No.1 004) (See Figure 15)To remove old solenoid valves:1. Remove back panel as outlined on page 20.2. Remove lead gOing from solenoid to pressureswitch No.2 (right pressure ) by disconnectingfrom pressure switch terminal.3. Remove lead from solenoid to TB-5 on terminal strip by disconnecting from terminal strip.4. Disconnect hose from exhaust port to solenoidvalve at the solenoid valve (bottom hose).5: Disconnect hose from solenoid to muffler coupl- .ling at the muffler connection first then disconnect other end of hose from solenoid.6. Remove two 8-32 nuts attaching solenoid tomounting bracket.7. Remove fitting from bottom of solenoid.8. The solenoid may be repaired, if it is not otherwise damaged (see How To Repair Solenoid,page 26). Otherwise, replace witih new solenoid.

To Install new solenoid valve:1. Replace fitting in bottom solenoid hand tight andthen tighten three more turns with a 9/168wrench. Then reconnect 68 hose to fitting.2. Replace 68 hose in right side of solenoid handtight and then tighten three more turns with a

9/168

wrench.3. Mount new solenoid valve on mounting brackewith 8-32 nuts,4, Reconnect one lead (slip on terminal) to spadterminal on pressure switch No', 2 (right pressure switch), See Figure 9, page 22.5. Reconnect second lead (fork terminal) to screwterminal 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 cookerto see i f solenoid will allow cooker to build uppressure, After pressure builds up to approximately 141/2 psi, solenoid should exhaust allowing pressure to drop to apprOximately 13 112psi, and then stop exhausting. If it needs adjusting, see "How to Adjust Pressure Swltch 8 ,on page 20,r

V _ ~ ~ L G

$CUNOI) KTG 8AICTfr. NO. 1995

fiJ . /'T. NO. .. .HOSE. lG. 10"PT. NO. 1 S 7 ~

Figure 15

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HOW TO REPAIR SOLENOID VALVE(USE TEFLON SEAL REPAIR KIT - PART NO. 1013

The soleno id Is a very expensive pa rt. Many timesit can be repaired at a much lesser cost than buying a new solenoid. The repairs consist of replacing the coli if It is burnt out or, most generaly re-placing the Teflon seal with a.Teflon Seal Kit, Pt.No. 101 3. It is very Important that the solenoid bereassembled correctJy or It will not work when putback together.To disassemble solenoid, see Figure 16, page27 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 diaphragm 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 tends to make 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 buying a new valve. 3.lf the coil Is good, It Is not necessary to disas semble the coli hOUSing. To detemine whether the co il Is good. measure the continuity be-tween the two black leads coming out of the front of the coli housing with a digital voltmeter. It should read about '81 (}'oomtt. i f it -reads Infinite ohms, the co li is bad. Replace It by proceeding to Paragraph 4, below. If the co li is good, skip Paragraph 4 and proceed to reassembling soleno id . 4. To replace the co il, remove the retainer clip

(Item No . 5). You may then remove the two ends and slip the old coli out (Item No.7). Re-place with a new coli. To reassemble the coil housing, put in new colis from the bottom slidIng the two black leads through the front threaded outlet Place composition paper insulating 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 reassemble the rest of the solenoid as shown in Figure 16, page 27. -26

To reassemble solenoid:1 . Clean base by soaking in a strong soap sotion.2. After base is cleane d and dried, replace wnew Teflon seal (Item No. 14) domed side in Teflon base (Item No. 15) cavity.3. Next place rubber diaphram (ltem No. 13)base cavity on top of Teflon seal (Item No. 14. Place activator guide (Item No. 12) in cavion top of rubber diaphragm (Item No. 13).5. Place plunger activator (No. 11) in hole of a

vator guide (Item No. 12).6. Place compression ring (Item No. 10) basecavity on top of activator guide (Item No. 17. Place co mpression plate (Item No .9) on tocompression ring (Item No . 10).8. Place plunger pin (Item No . 8) in coli hous(Item No.6) hole on bottom of coil housing wlittle end up. Important: Little end must be

or solenoid will not wOrk.9. Place plunger (Item No.4) in hole on top oco il housing (Item No.6). Im portant: Smhole In flat part of plunger should be down w

p l ! J _ o g , e r n d . p J . u n g . e t P l o ~ l i l . J ; . . . . 1 tshould be some give or "sp ring when plunpin Is pressed against bottomof plunge r. NoIf e n clip (Item No. 5}is not in place, Itcause solenoid to chatter.10. Place coil housing assembly (Item No. 6) otop of Teflon base (Item No. 15) with wire olet opposite hose outlet. Make sure plungpin (Item NO.8) remains in correct.positiocoli housing during assembly.11. lighten assembly together by tightening fo8-32 nuts on screws.12. Reconnect hose and wires and test as desced In ItHow to Replace Solenoid Valve", pa25.
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- . .....

Figure 16

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~-27


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HOW TO CHANGE MAIN HEATING ELEMENT(Part No. 5810, BB) (Part No. 1810, Be & BCD) see Figure 17

Note: It is not necessary to change elements to matchvoltage on which the unit is actually operating. Forexam ple. to change from a 240V machine to a 208Vmachine (or Just the opposite). it is a matter of dropping one element or adding one. See. wi ring diagramson pages SO, 31 and 32.To determine a defective element, follow thisprocedure:

1. Remove back panel and bottom control panel cover as outtined In. ~ o w to Remove Back Panels on page 20. 2. Remove two wires and Jumper busses from maJn elements. In each machine, there are four elements. Therefore. you must remove eight nuts,

washers, and two each sho rt jumperand long jumper busses. 3. Determine defective element by measuring resistance with an ohmmeter. The resistance will be 37.4 ohms for a BB and 35 ohms for a BC and BCDelement. The element is defective if it does notread the specified ohms 5%. If the element isburned out, it will either measure less ohms thanshown above or infinite ohms. That is. it willeither show short to grouncr or an open circuit. Ineither event, the element must be rep laced. In eachmodel. the four elements are the sam e wattage. Inthe BB, each element is rated at 1540 watts at 240V.In the Be and BCD, each element Is 1650 watts at240V.To replace th e element, see Figure 17 on page29 and follow Instructions below:1. Remove four 10-24 truss head screws from red skirt cover and remove I t 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 removIng four .10 sheet metal screws. 4. Remove element end cap by removing four .10 sheet metal screws. 5. Remove nine 10-24 truss head screws wh ich fasten the top to the bottom cabinet assembly and remove bottom cabinet assembly. 6. 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

of the clamp band. The clamp and will then fleenough to slip of f cooker.7. Remove the insulation from the heat chamber o8. Remove two 114-20 bolts from the elemen t clamband. Remove element clamp and by sp readinand removing.9. Remove defective element by spreading and reming .

10. Replace defective element with good element.11. Place clamp band in place and tighten two 1/4-botts.12. Replace heat chamber insulation.13. Replace insulation cfamp band by bolting two 1

20 on the front lips then fasten to the top with th10-24 nuts.14. Replace element end cap by fastening to insulatclamp band with four '10 sheet metal screws.

. 15. Rep lace bottom control panel assembly by fastIng to the Insulation clamp band with four sheetmetal screws.

16. Replace bottom cabinet assembly (with casters) afasten to the top with nine 10-24 truss head scre17. Replace drain valve handle and adapter by screIng 318 nut onto drain valve stem. Align handleJoosenlng the alignment nut correctty positioning drain valve handle. If the drain valve Is closed,correct position Is horizontal to the cabinet andthe right.18. Fasten red skirt cover to bottom of cooker cabinwith four 10-24 screws.19. Tum cooker back over on its casters and reconnwi res and jumpers for the proper voltage. See, 'Wing Dlagram-, pages 30,31 and 32.20. Test unit with a quart of water and make any necsary adjustments to the pressure switch to be sthat they are adjusted to the proper values.21. Fasten bottom control panel cover and back paback In place.


30/38

-- WlETmr= 1 1 I ~ ; "tASI!IS'

Figure 17


31/38

UO ASSV. COMPlETE WI TOP ~ o u : at O-RING ~ TOP HANDLE W I SCREWS. PT. NO. 2076PTNO.IS1S 0oWINAl STRIP ______ " .

PT NO. 1 ' ~ADAPTER. 51,4, PRESSURE SWI TCH ).IANIFOLD,PT NO . 1540 SAFETY VAllIE ......PT NO. 0075 \

PRESS URE SWITCH, SlNCLE, PT NO . 100.1 EJECTOR VAlVEPT NO. 0065

SOLENOID VAllIE. PT NO; 1HOSE , LG, 6", PT NO. 156

CONTR OL 80)( ASS'1i'T NO. 15115POWER R r v . Y ~ ~PT NO. 0317 . ~

PT NO. 1002(60 P.E.RTZ)

ELBOW, !..C, lilT, PT NO. 111

(rJ 1950UGHT. REO, PT NO. 152 I

15;'1ADAPTER, ElBOW,HOSE. 7" (SIMI..L.), PT Mel. 0726 lSI,6.OAPTER, ElBOW, PT NO. 1110 GAUGE . PRESSURE, PT NO. .MANIFoLD loSSY, INSERT. I'T NO. 1 7 2 8 ~ ~ ,

AMPTER SlRAICHT. LC, PT NO. 1' 08 / 'HOSE. 10", Le, PT NO. 157J /"

ADAPTER. STRAlGKT, Le. PT NO. , lOBKNOB. CLAMP DOWN, PT NO. 1720 - A'O'.. EACH ON aB, II EACH ON Be '\JI4: 12 EAcH ON BCD .

T-80LT, PT NO. 1710V' I I04 EACH ON SS, 8 EACH ON Be t ? 1 ~ Elf.Iol[NT, MAIN,. 1 5 ~ 0 mons, BB, PT NO . 5810& 12 EACH ON BC D LfJ.4E'NT . w.lN, 1650 WAn'S. 8e II. BCO. PT NO . lBl... EACH ON DB &8C, 8 EACH ON Dcn .JUMPER BUSS, SHOR'TPT 1'10.18972WHON88&BCEACH ON Reo

JU J.lPER BUSS , LONPT NO.18BS2 EACH ON aB 4: BC.. EACH ON oeDINSULATIO N, HEAllNG CHAMBER, PT NO. 1875 . J f.ACH oN j( Be, B EACH ON DCO


32/38

_PT NO. ;gOO ~ '" ElEMENT OlD CAP171 ~ ~ . 1 9 ~ O .BaT. CONTROL COIIrR. -O r r O ~ UWI"'-l---

PT NO. HI5S ' INSULATION ClAMP &.NOPI NO. 5970. OBPT NO. 1970. Be " BCD

... .. ... ..,.........,, ...........

CABINET Bono."I'T NO. )920. Ba--- PT NO. 1920. BCPT NO. 692.0, BCDDIWN VIlLI/E, II I NO. 0722OIWN V/lL1/E A{W>1ER ASS'f, PT NO . 15911MJ.J ORAlN V/lLI/E DRIO'BACK. CABINET SKIRT PT NO. 20.17PT NO. 5937, BB ~ PT NO. 1937, Be CABINEl SI


33/38

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