Summary of Contents for Sub-Zero Wolf BBQ242BI
- Page 1 subzero.com 800.222.7820 Service Manual General Information Controls & Operation Installation Information Component Access & Removal Troubleshooting Guide Technical Data...
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Page 2: General Information
Technicians. The information and images are the copyright property of Wolf Appliance, Inc., an affiliate of Sub-Zero, Inc. Neither this manual nor any information or images contained herein may be copied or used in whole or in part without the express written permission of Wolf Appliance, Inc., an affiliate of Sub-Zero, Inc. -
Page 3: Warranty Information
General Information O O U U T T D D O O O O R R B B B B Q Q G G R R I I L L L L S S WARRANTY INFORMATION WOLF APPLIANCE CO. LLC FITCHBURG, WI MODEL BBQ- This page contains a summary of the 2 &... -
Page 4: Model Features
General Information OUTDOOR B B BQ G G RILLS MODEL FEATURES: All Models: Wolf BBQ grills are constructed with heavy duty 18-gauge stainless steel. The hood is a two piece stainless steel design with a handle. All grates are made from porcelainized cast iron. A grill scraper and protective cover is pro- vided with each unit. -
Page 5: Model Number Key
General Information OUTDOOR B B BQ G G RILLS MODEL NUMBER KEY Refer to this key for an example of the model numbers. Model: BBQ362BI-LP Product Type Size Side Burners Features Fuel Product Type Size 24 - Grill Space 30 - Grill Space 36 - Grill Space Side Burners Features... - Page 6 General Information Notes OUTDOOR B B BQ G G RILLS TOP CONFIGURATIONS FOR OUTDOOR BBQ GRILLS Configuration Description Model # BBQ242BI 24” Grill with Two Open Burners, Built-In (Nat. Gas) BBQ242BI-LP 24” Grill with Two Open Burners, Built-In (LP) BBQ242C 24”...
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Page 7: Theory Of Operation
Theory of Operation OUTDOOR B B BQ G G RILLS THEORY OF OPERATION A service technician should understand how a gas appliance operates before attempting to service the appliance. This section provides descriptions of the different types of fuel gases and explains gas heating values. A definition of specific gravity of gas is given along with its characteristics and effects. - Page 8 Theory of Operation OUTDOOR B B BQ G G RILLS Principles of Gas Combustion: Combustion - When oxygen acts with a substance to produce large amounts of heat rapidly. Requirements for Combustion - There are three required elements for combustion to occur; Fuel (Gas), Oxygen (Air) and Heat (Ignition Temperature, which for gas is between 1100°F/593°C and 1200°F/649°C).
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Page 9: Burner Components
Theory of Operation OUTDOOR B B BQ G G RILLS Burner Components: Gas Orifice - An opening or hole which regulates or limits the amount of gas flowing to a burner. Gas flow rate (vol- ume) depends on the size of the orifice (hole) and the gas pressure at the inlet of the orifice. Air Shutter - This is used to adjust the size of the primary air inlet area and therefore controls primary air flow. -
Page 10: Types Of Burners
Theory of Operation OUTDOOR B B BQ G G RILLS Types of Burners: Blue Flame Burners - All Wolf BBQ burners are blue flame burners. With this type of burner, primary air is mixed with the fuel gas before the gas reaches the burner ports. An orifice is used to regulate gas flow to the burner. Air which is mixed with the gas inside of the burner body enters through openings in the burner body. - Page 11 Theory of Operation OUTDOOR B B BQ G G RILLS Operation of the Wolf BBQ Grill About the Wolf BBQ The grill grates are composed of five-inch heavy duty porcelain cast iron and are designed for easy handling and cleaning. Just below the grill surface are the stainless steel heat radiants which concentrate the heat. The Wolf BBQ design eliminates the use of briquettes or lava rock.
- Page 12 Theory of Operation OUTDOOR B B BQ G G RILLS Manual Lighting Procedure You may manually light the grill burners by inserting the match/lanyard holder or a butane lighter into the 1/2” diame- ter hole above the grill valve knob (Fig.
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Page 13: Cleaning And Maintenance
Theory of Operation OUTDOOR B B BQ G G RILLS Cleaning and Maintenance Burner Grates The grates are composed of durable cast iron with a porcelain enamel finish. Operating the grill on High for a few minutes after cooking will help to burn off any excess food. -
Page 14: Installation Information
Installation Information OUTDOOR B B BQ G G RILLS INSTALLATION INFORMATION This section of the manual covers some of the installation issues that a service technician may need to know when servicing a Wolf BBQ. If additional installation information is needed after reviewing this section of the manual, please refer to the Installation Guide or contact the Wolf Appliance Customer Service Department. - Page 15 Installation Information OUTDOOR B B BQ G G RILLS Pre-Installation Specifications Overall / Pre-Installation Dimensions Model BBQ242 Model BBQ36 Model BBQ362 Model BBQ48 A Overall Width of Grill 36” 36” 48” 48” B Width of Hood 24” 36” 36” 48” C Rough Opening Width (Combustible Enclosure) 38 1/4”...
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Page 16: Gas Requirements
Installation Information OUTDOOR B B BQ G G RILLS Gas Requirements Gas Pressure: NOTE: All Wolf BBQ’s are manufactured as either natural gas or LP gas. Natural Gas Manifold Pressure Standard natural gas orifices on the BBQ are set for 5” WC (Water Column Pressure). A natural gas regulator is provided. - Page 17 Installation Information OUTDOOR B B BQ G G RILLS LP Gas Hook Up An LP Wolf BBQ is equipped with a five foot hose, regulator and unfilled 20 pound gas cylinder. This connection is done with the cylinder located inside of the cart. See Fig.
- Page 18 Installation Information OUTDOOR B B BQ G G RILLS Leak Testing A leak test should be performed every time the gas cylinder is connected to the regulator, and whenever part of the gas system is disconnected or replaced. This applies to both natural and LP gas. Test for leaks at the cylinder valve, cylinder welds, regulator (especially attached to cylinder valves), hose and con- nections.
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Page 19: Component Access And Removal
Component Removal OUTDOOR B B BQ G G RILLS COMPONENT ACCESS AND REMOVAL This section explains how to access and remove components from a Wolf Outdoor BBQ Grill. Depending on which component you are going to access or remove in the following sections, you may have to remove some components first. - Page 20 Component Removal OUTDOOR B B BQ G G RILLS OPEN BURNER COMPONENTS: Step-Up Frame The step-up frame is stainless steel and is used to ele- Components include; Open Burner Cover, Open Top vate the rear open top burner. To remove the step-up Grates, Step Up Frame, Burner Head, Front &...
- Page 21 Component Removal OUTDOOR B B BQ G G RILLS Front Venturi Spark Ground Strap The burner head sits on top of the front venturi. The The spark ground strap is mounted over the spark elec- front venturi sits on the burner support bracket and trode and is secured to the spark electrode mounting slides over the burner valve orifice.
- Page 22 Component Removal OUTDOOR B B BQ G G RILLS Burner Support Bracket Spark Electrode Mounting Bracket The burner support bracket is used to support the open The spark electrode mounting bracket is used to mount top burners. To remove the burner support bracket you the spark electrode to the pilot burner tube.
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Page 23: Grill Components
Component Removal OUTDOOR B B BQ G G RILLS GRILL COMPONENTS: Components include; Broiler Grates, Radiant, Stainless Steel Burner, Spark Electrode Ground Strap, Spark Electrode Mounting Bracket and Spark Electrode. NOTE: To remove the following components, you must first raise the front hood. Broiler Grates The grilling surface is composed of numerous broiler grates. - Page 24 Component Removal OUTDOOR B B BQ G G RILLS Spark Electrode Ground Strap Spark Electrode The spark electrode ground strap secures the spark The spark electrode emits the spark supplied from the electrode to the spark electrode mounting bracket. To rotary igniter to light the gas in the burner tube.
- Page 25 Component Removal OUTDOOR B B BQ G G RILLS FRONT CONTROL PANEL COMPONENTS: Rotary Igniter To remove the rotary igniter, first remove the rotary Components include; Control Knob, Igniter Knob, igniter knobs and the control knobs. Remove the con- Control Panel, Rotary Igniter and Match Holder with trol panel and unplug the electrode wire from the rotary Lanyard.
- Page 26 Component Removal OUTDOOR B B BQ G G RILLS COMPONENTS BELOW THE BULL NOSE: Components include; Bull Nose, Burner Valve, Burner Valve Orifice Hood, Valve Adapter, Tee, Nipple, Connector, Pilot Valve and the Manifold Pipe. Bull Nose Removal To remove the bull nose, extract the two screws from the left and right legs of the bull nose and lift the bull nose from the unit.
- Page 27 Component Removal OUTDOOR B B BQ G G RILLS Valve Adapter and Tee The valve adapter is threaded onto the end of the infrared rotisserie burner valve. It allows the tee adapter to be threaded on, so the rotisserie burner valve can supply gas to the pilot valve and the safety valve for the infrared burner.
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Page 28: Hood Components
Component Removal OUTDOOR B B BQ G G RILLS HOOD COMPONENTS: Components include; Rotisserie Rod with Fork, Rotisserie Motor, Motor/Rod Support, Hood Handle, Front Hood, Rear Hood Top, Rear Hood Left and Right, IR Burner Cover with Handle, Pilot Shield, Infrared Burner, Pilot Burner, Spark Electrode, Rear Splash Panel, Side Plate Shelf, Side Plate Shelf Brackets and Belly Bar with Brackets. - Page 29 Component Removal OUTDOOR B B BQ G G RILLS Rear Hood Top Hood Handle The rear hood top is connected to the right and left side The hood handle is attached to the hood from the hood, and is slotted for ventilation. It covers the inside.
- Page 30 Component Removal OUTDOOR B B BQ G G RILLS Infrared (IR) Burner Cover with Pull The infrared burner has a stainless steel cover that pro- tects it when not in use. The cover has two tabs that fit into grooves which are cut into the rear splash panel. When the tabs are inserted into the grooves the cover hangs onto the rear splash panel.
- Page 31 Component Removal OUTDOOR B B BQ G G RILLS Pilot Burner The pilot burner is lit by a sparker and maintains a standing pilot light for the infrared burner and flame sensor as long as the infrared burner valve is in the on position.
- Page 32 Component Removal OUTDOOR B B BQ G G RILLS Side Plate Shelf Belly Bar and Brackets The Side Plate Shelf is a stainless steel fold down shelf The belly bar is a stainless steel tube that is mounted to that is mounted to the side of the unit. It can be lifted the side of the unit with two mounting brackets.
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Page 33: Rear Panel Components
Component Removal OUTDOOR B B BQ G G RILLS REAR PANEL COMPONENTS: Components include; Rear Panel, Safety Valve and Gas Tubing WOLF APPLIANCE CO. LLC FITCHBURG, WI MODEL BBQ- SERIAL INPUT RATING EACH MAN. BURNER-BTU / HR. PRESS. GRILL ROTISSERIE OPEN BURNER ROTISSERIE MOTOR ELECTRICAL RATING... - Page 34 Component Removal OUTDOOR B B BQ G G RILLS Infrared Gas Tubing This is a flexible gas line that goes between the safety valve and the infrared burner. Once the flame sensor on the pilot burner is hot enough to open the safety valve, it will supply the gas from the safety valve to the infrared burner. To remove this flexible gas tube you will have to turn off the gas supply.
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Page 35: Cart Components
Component Removal OUTDOOR B B BQ G G RILLS CART COMPONENTS: Components include; BBQ Chassis, Door Handles, Door Assembly, Doorstops, Top Catch Holder, Magnetic Catch, Bottom Panel, Rear Panel, Side Panel, Top Trim, Swivel Caster w/Brake, Caster Locking Bracket, Non- Swivel Caster, 48"... - Page 36 Component Removal OUTDOOR B B BQ G G RILLS Top Catch Holder The top catch holder is located behind the cart doors and centered at the top of the cart frame. It is a bracket that houses the magnetic catch for the doors. To remove this you will need to open the doors.
- Page 37 Component Removal OUTDOOR B B BQ G G RILLS Rear Panel To remove the rear panel you will need to pull the cart out so you have access to the rear of the unit. Now extract the screw from the rear panel and lift the rear panel off of the cart.
- Page 38 Component Removal OUTDOOR B B BQ G G RILLS Swivel Caster with Brake There are two swivel casters mounted on one end of the cart assembly. These casters swivel 360 degrees and allow the cart to be turned in any direction. To remove the swivel casters you will need to prop the unit up on one end so you have access to the swivel caster under the cart.
- Page 39 Component Removal OUTDOOR B B BQ G G RILLS Cart Shelf (48"Cart Only) To remove the shelf you will need to open the cart doors. Now extract the screws that mount the shelf to the cart partition. Lift the left side of the shelf off of the tabs on the side panel and pull the shelf out of the cart assembly.
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Page 40: Troubleshooting Guide
Troubleshooting Guide OUTDOOR B B BQ G G RILLS TROUBLESHOOTING GUIDE This section of the manual contains the General Troubleshooting Guide which will help the Service Technician trou- bleshoot a Wolf BBQ Grill. How to Use the Troubleshooting Guide The troubleshooting guide table of contents shows how the troubleshooting guide is laid out. The troubleshooting guide is organized into component areas with the most common problems listed first. -
Page 41: Test / Action
Troubleshooting Guide OUTDOOR B B BQ G G RILLS PROBLEM POSSIBLE CAUSE TEST / ACTION A. NO SPARK Defective rotary igniter Replace rotary igniter Defective or dirty spark electrode Replace or clean spark electrode Spark electrode wire unplugged from rotary Reconnect spark electrode, may need to crimp igniter end of electrode for tighter connection... - Page 42 Troubleshooting Guide OUTDOOR B B BQ G G RILLS PROBLEM POSSIBLE CAUSE TEST / ACTION INCOMPLETE FLAME LP regulator hose dropping Coil hose around Cylinder (See pg. 3-5) Clogged, broken or worn out burner Check, clean and/or replace burner Plugged orifice Clean orifice Air shutter out of adjustment Adjust air shutter...
- Page 43 Troubleshooting Guide OUTDOOR B B BQ G G RILLS PROBLEM POSSIBLE CAUSE TEST / ACTION O. ROTISSERIE HANDLE Open top burners used when using rotis- Handle needs to be removed when using open MELTED serie top burners HOOD IS DIFFICULT TO Inner hood liner warping from heat Replace hood assembly RAISE AFTER HEATED...
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Page 44: Technical Data
Technical Data OUTDOOR B B BQ G G RILLS GAS PRESSURE Natural Gas and Liquid Propane Maximum 14” WC Gas Supply Line Pressure Natural Gas Minimum 7” WC Liquid Propane Minimum 11” WC Natural Gas Manifold Pressure, with Standard Orifice 5”... - Page 45 Technical Data OUTDOOR B B BQ G G RILLS Ensure burner is fully seated Towards ther rear of the bracket Fig. 6-1 Proper Charge Tube Length is 3 1/8” Center the Igniter between the charge ports 3/4" Fig. 6-2 Igniter Module and Gas Charge Tube Assembly...