Z Grills MINI - Smoker Grill Manual

Quick Reference Guide

Technical Specifications

Food Minimum Temperature Chart

• When cooking meat and fish use food probes to monitor the internal temperature.
  Internal temperatures can also indicate how well cooked it is.
• Minimum food temperatures must be reached to kill bacteria ensuring the meat is safe to eat.
• The chart below is provided as a guide only. Check online for more detailed temperature values for the specific food you are cooking.

Minimum Safe Internal Temperatures

Assembly Instructions

Assembly Process

• Follow the step by step assembly instructions on the following pages.
• Wear gloves when handling the grease tray as it has a layer of oil to prevent rusting during storage in the box.

Tools and Fasteners

• The screws, washers and screwdriver are provided in the shrink-wrapped package. Note the letter code beside each item as they are referred to in the assembly instructions.
• Take care when doing up screws not to damage the heads as they are made of a corrosion resistant metal alloy which is not very hard.
• Always start the thread by hand before tightening with the screwdriver.

Food Temperature Probe

• The food temperature probe plugs into the controller to show the food's internal temperature. View the probe temperature on the controller screen.
• The cable can withstand high temperatures so can stay in the grill during operation.
• It is ok to close the grill lid on the cable.

1. LEGS
   
2. LID HANDLE
   
3. SIDE HANDLES
   If packing in a car or caravan you may wish to leave off (or temporarily remove) the side handles for a smaller overall size. Take care lifting the grill as it is heavy.
   Never move whilst still hot.
   
4. GREASE TRAY
   The grease tray sits in the grilling box with the spout extending through the hole in the rear. Push the grease tray to the back, ensuring an even gap on the left and right sides for balanced hot air flow from below.
   Cover with foil
   Cover the grease tray with a layer of heavy duty foil for easy cleaning. Wrap the foil tightly around the edges of the grease tray so it does not block the hot air flow from around the sides.
   Wipe off excess oil
   Wipe off excess oil with a paper towel before doing the burn in.
   
5. GRILL RACK
   Sit the grill rack in over the grease tray.
   The grill rack are ceramic coated. Only clean with a wet cloth, BBQ wipes or Koala Claw (BBQ cleaning tool). Do not use stainless steel brushes or strong chemicals as they will damage the ceramic coating.
   
6. GREASE BUCKET
   Hook the grease bucket onto the back of the grease tray. Remove the bucket before moving the grill as it can easily fall off.
   Lining the bucket with foil or placing an empty can inside is a good idea to allow for easy cleaning.
   

Initial Startup Instructions

1. Remove the grill rack and grease tray from the grill.
2. Open the hopper lid to check that there are no foreign objects in the hopper or auger.
3. With the controller dial in the OFF position, plug in the power cord into 240V AC grounded power supply. A minimum of 1.2 Amp (300Watt) power supply is required if running off a battery.
4. Turn the dial to the SMOKE.
5. Check the following:
   • Confirm the auger is rotating (turns very very slowly and will stop/start intermittently)
   • Listen for the fan operation and hold your hand above the fire-pot to confirm air flow
6. Pour some wood pellets into the hopper (up to the safety grate level is sufficient) and shut the hopper lid.
7. Turn the controller dial to the highest temperature (232ºC). It will take 7-8 minutes for the pellets to feed through the tube and begin to drop into the fire-pot. If LEr is displayed, just turn to OFF and then back to 232ºC to continue feeding wood pellets.
8. Once pellets begin to drop into the fire-pot, turn the dial back to OFF then immediately to SMOKE to commence the startup cycle. After 2-3 minutes a big cloud of smoke will be released then a fire will be established.
9. Once the fire is roaring, carefully place the grease tray and grill racks back into the grill. Next complete the New Grill Burn-In, or normal cooking if already burnt-in.

TIP:
If the grill ever runs out of pellets, following steps 7 and 8 above to prime the feed tube with wood pellets again, then startup as normal.

New Grill Burn-In

This process runs the grill at the highest temperature setting (burning wood pellets for heat) to burn off any surface oils on the grease tray (wipe off excess oil first with paper towel). This must be completed before cooking any food. The smoke will have an oily odour, so avoid breathing in the smoke or completing the burn-in near an open window of your house.

1. If you have just completed the Initial Startup process, the unit should already be running on the SMOKE setting with the grease tray (no foil) and grill racks all placed inside. Proceed to step 3.
2. If currently OFF, open the grill lid and turn to SMOKE. Once lots of smoke appears, then begins to clear and you hear the roaring sound of the fire, proceed to step 3.
3. Close the grill lid and turn the dial to 232ºC.
4. Run on the 232ºC setting for 45 minutes. The grill should reach over 200ºC after about 15 to 20 minutes. During the burn-in the grill may not reach 232ºC, which is normal.
5. After 45 minutes, turn the dial to SMOKE. If you accidentally turn to OFF, just immediately turn back to SMOKE.
6. Leave the grill running on SMOKE setting for at least another 10 minutes to allow the fire to die down, then turn the dial to OFF. The fan will continue to run for about 10 minutes before turning itself off.
7. Once cooled down, wipe the grill racks with a moist cloth and cover the grease tray with foil before using to cook food. Follow the Normal Operation process to start the grill up and begin cooking.

Normal Operation

Startup Procedure

1. Plug the grill into power (240V AC, minimum 300 Watt, 1.2 Amp power supply)
2. Check to ensure there are enough wood pellets in the hopper.
3. Open the grill lid and turn the dial to SMOKE.
4. The controller will turn on the ignition rod (to light the fire), run the fan at full speed, and intermittently rotate the auger to push wood pellets into the fire-pot.
5. After 2-3 minutes a big cloud of smoke will be released.
6. Once the smoke clears and the roaring sound of the fire can be heard, close the grill lid.
7. Turn the controller dial to the target temperature setting or leave on SMOKE setting.
8. Wait for the grill to reach the target temperature before placing in food.

Operating Mode

1. Once the grill has successfully started up and exceeded 60ºC the controller will turn off the ignition rod and commence normal operating mode.
2. The controller logic is basically as follows:
   • IF LOWER than the target temperature, deliver more pellets into the fire-pot
   • IF HIGHER than the target temperature, deliver less pellets into the fire-pot
3. Each time pellets are delivered into the fire-pot (roughly once every 60 to 90 seconds) and begin to burn, heat is released resulting in small temperature swings around the target, which is normal.

Shutdown Procedure

1. If operating at 162ºC or higher, first turn to SMOKE setting for 10min to allow the fire to die down. For lower operating temperatures proceed directly to step 2.
2. Turn the controller dial to OFF
   • The auger will stop rotating and no more pellets will be delivered into the fire-pot.
   • The fan will run for about 10 minutes until all pellets in the fire-pot burn out.
3. Once the fan has stopped, the power supply to the grill can be unplugged/switched off.

Power Cut During Operation
During operation, if power is disconnected:

• If power immediately comes back on: Turn the dial to OFF, then to the desired temperature target to continue normal operation. A temperature spike will likely occur, so just wait for the temperature to gradually stabilise back down.
• If no power for more than 30 seconds: OPEN THE GRILL LID and turn the dial to OFF then back to SMOKE. Once the roaring sound of the fire can be heard, close the lid and turn to the desired temperature target (if still cooking).

Temperature Issues

Changing from High to Low Temperature Setting
If the grill has been operating at a high temperature and is then set to a lower target, the grill will take a long time to cool down as fire in the fire-pot will keep producing heat.
The temperature will drop much slower in hot weather.
To drop the temperature more quickly:

• Open the lid to release heat until the controller displayed temperature drops close to the new, lower target, then shut the lid and continue cooking.
• Do not keep the lid open too long as if the temperature drops below the new target then too many pellets will be delivered causing a temperature spike.

Temperature Spikes
Temperature spikes up to 120ºC are common in the first 10 to 15 minutes after startup even when set to a lower target due to the large amount of pellets delivered into the fire-pot.

• Open the lid for a minute to release some heat, or just wait for the temperature to gradually come back down, which may take 5 to 10 minutes.
• Next time, leave the lid open a bit longer after the initial cloud of smoke clears to release some more heat.
• The grill will gradually settle at the desired target but small swings of +/- 5ºC are normal. Because the heat is indirect this temperature cycling will not adversely effect the cooking of food.
  Opening the lid too often or for too long can cause temperature spikes as more pellets are delivered into the fire-pot. Always remember: "If you keep looking, you're not cooking!"

Temperature Display vs Grill Rack
The temperature on the LCD screen may differ by +/- 10 to 15ºC from the grill rack temperatures, especially during the heating up phase. This is normal. Relax!

Cleaning the Grill

Clean the grill after each use, as accumulation of grease, ash and soot can increase the risk of a grease fire and result in inefficient operation.

Grease Tray & Bucket

• Remove foil from the grease tray and wipe off any surface grease.
• Dispose of any grease in the grease bucket and wash clean with warm soapy water. For easy clean up, line the bucket with foil.

Grill Rack

• Use a Koala Claw wood scraper or other gentle material to scrape off any large chunks.
• Do NOT use a stainless steel wire brush as it can damage the ceramic coating.
• Wash in hot soapy water or just wipe down with a moist cloth or BBQ cleaning wipes.
• Do NOT use acidic or strong chemical cleaners as they may damage the grill rack ceramic coating.
  Cast Iron BBQ Hotplate

Fire-pot

• Ash accumulates in the fire-pot and surrounding area and needs to be vacuumed out after each long cook or every 3-4kg of wood pellets usage.
• Only vacuum out ash when the grill is cold, switched OFF and unplugged.
• Some wood pellets produce lots of ash so may need to be cleaned after every cook.
• If any grease has dribbled down into the fire-pot area, clean with BBQ cleaning wipes.

Vents

• Once every 50+ hours of use, clean off any soot around the air vents on the rear of the lid with an old toothbrush and wipe clean with BBQ wipes.

Grill Surfaces

• Wipe down the inside and outside of the grill with BBQ cleaning wipes, or warm soapy water and moist (not too wet) cloth.
• Cover the grill with a protective cover when not in use if stored outdoors. The grill must not be exposed to rain.
• Gently clean the temperature sensor inside the grill with wire-wool to ensure accurate temperature readings.

Food Temperature Probe

• Food probes must be scrubbed thoroughly after each use with hot soapy water to avoid food contamination.
• Do not immerse the entire probe or cable in water.
• Avoid twisting or kinking the cable as it may be damaged.

Wood Pellet Use & Storage

Storage

• There are small holes in the wood pellets plastic bags to release air, so never sit bags on wet surfaces, or directly on outdoor concrete or wood as moisture may be absorbed.
• Once a bag of pellets has been opened, seal the top of the bag, or even better, store in a plastic bucket with a well sealing lid.
• Do not fill up the hopper every time you use the grill, as the pellets may end up sitting exposed to humid air for a long time. Only pour in as many as required for the cook.
• If wood pellets get moist they will become soft and lose the shiny surface appearance. Never use pellets that are moist as they will not burn well and once dry can block up the auger feed pipe, preventing the auger from rotating freely.
• Avoiding pouring the wood pellet dust from the bottom of the bag into the hopper.

Cleaning

• If not planning to use the grill for several weeks or longer it is a good idea to clear pellets out by running the grill until empty, especially in humid climates. Follow these steps:
  
  • With the grill turned OFF, scoop out all the pellets above the protective grate with a plastic cup or bowl.
  • Remove the two screws (front and back) that secure the top of the hopper and grate in place. Lift off the top of the hopper and scoop out the remaining pellets. Replace the top of the hopper.
  • Start the grill as normal and run at a high temperature setting until the remaining pellets in the hopper are used up. The grill will automatically turn OFF and display LEr
  • (low temp error) once the pellets run out and the temperature drops, which is normal.
  • Once cooled down, vacuum out the bottom of the hopper and fire-pot.
  • Before next use, complete the Initial Startup Process again

Pellet Usage

• The grill only uses as many pellets from the hopper as required to maintain the target temperature and will NOT use all the pellets in the hopper each time it is used.
• Pellets are used at around 0.2kg per hour at low temperatures (<121ºC) and up to 0.5kg per hour at high temperatures.
• Australian hardwood pellets tend to burn 15-20% longer than oak/fruit wood blends. What Pellets to Use?
• Any wood pellets designed for wood pellet smokers should work fine in this grill.
• As a general guide:
  • Australian hardwood pellets = Slow burning (more heat); Low ash; Subtle flavour.
  • Oak/fruit blend pellets = Fast burning (less heat); High ash; Stronger flavour.
• While you can use a single type of wood pellet, it is often a good idea to mix Australian hardwood pellets with oak/fruit blend pellets for a longer burn time, lower ash and great smoky flavour. ⅓ oak/fruit blends to ⅔ Australian hardwood is a good mix ratio.

Using a BBQ Hotplate

The Z Grills MINI BBQ hotplate is an optional accessory specifically designed to fit in Z Grills MINI smokers for hotplate BBQ style cooking.
The cast iron hotplate is pre-seasoned but will benefit from additional oil seasoning. Season, clean and care for the hotplate like any other cast iron cookware.

How to use

• Remove the grill rack and grease tray.
• Sit the hot plate directly over the fire-pot, either smooth or ridged side up.
• Cast iron takes times to heat up, so place in the grill as early as possible, not just before placing on food.
• The grill will loose heat rapidly with the lid open, so if you need to flip food, do it fast and close the lid. Remember,If you keep looking, you're not cooking!
• Never pour cold liquid onto a hot cast iron plate as it can crack due to rapid cooling.
• Avoid spilling food and oil over the edges of the hotplate down into the fire-pot area as it will mix with ash and be a mess to clean up and could lead to a dangerous grease fire.
• If any food or grease spills down into the fire-pot box, wait until the grill has cooled down and wipe up with paper towel or BBQ cleaning wipes.
• Clean the hotplate with hot soapy water. Use a plastic brush (never metal) to scrub if required. Dry thoroughly and lightly oil before storing.
• If the hotplate shows signs of rust, rub back and season again the same as any cast iron cookware. There are many tutorial videos online with step by step instructions.

Scan to get a MINI BBQ Hotplate or to learn more

Controller Operation

The digital PID controller monitors the temperature sensor inside the grill and turns on/off the auger motor to deliver wood pellets into the fire-pot.
The grill internal temperature (GRILL) and food probe (P TEMP) are constantly displayed in degrees Celsius. Two small dots will flash on the display during startup until the temperature increases enough to indicate the fire has been established.

Controller Dial Settings
The controller is very easy to use, just turn the dial to the target temperature.

OFF setting

• Ensure the dial is set to OFF when plugging into power supply otherwise error ER2 will be displayed. To reset ER2, turn to OFF, disconnect then reconnect to power.
• Switch to OFF after using the grill. The fan will run for 10 minutes to burn the fire out before turning itself off.
• Do not unplug the grill from power until the fan has turned itself off.

SMOKE setting (Max smoke & Starting up the grill)

• Turn the dial from OFF to SMOKE to startup the grill (with the grill lid open).
• SMOKE setting can also be used to provide the maximum amount of smoky flavour to food. This is generally only used for the first 30 to 90 minutes of cooking before setting at a higher temperature to cook the food.
• On the SMOKE setting the controller will target an average temperature of 75ºC but with large temperature swings of up to +/- 10ºC, which is normal.

Temperature settings (82 ~ 232ºC)

• Target temperature settings are shown in both Celsius and Fahrenheit on the controller face plate, but only displayed in Celsius on the controller screen.
• Once the temperature setting is changed, the grill will slowly adjust to the the new target.
• It is normal for the temperature to overshoot a new target before swinging above and below the target and gradually stabilising.

Troubleshooting

Visit zgrills.com.au/help or scan the QR code for the latest troubleshooting guides and useful articles. Scan to visit our help site

Wiring Diagram

Spare Parts List

If a component is damaged, lost or just worn out through normal use, spares are available. Please refer to the chart below for most common spare components.
Contact support@zgrills.com.au to order spare parts.

Error Codes

Error codes will be displayed on the controller LCD screen. All grill operation will cease when there is an Error, so the problem must be solved before the grill can operate normally again.
Check Troubleshooting for more detailed information, or scan the QR code beside the error to visit our help page online for a more detailed explanation.

Er1 = Temperature Sensor Error

• Controller is not receiving a signal from the temperature sensor.
• May be due to bad wire connection on the controller, or damaged cable.

Er2 = Controller System Error

• Reset the controller by following these steps:
  • Switch the grill to OFF then unplug from power.
  • Plug the grill back in then turn to SMOKE to start normal operation
• Er2 will be displayed if the controller dial is already turned to a temperature setting when plugging into power.

LEr = Low Temperature Error

• Grill internal temperature has fallen below 49ºC for too long.
• Possible reasons include:
  • Grill may have run out of pellets (if mid cook)
  • Fire has gone out due to moist pellets or excessive ash (if mid cook)
  • Ignition rod is not operating (if during startup period).

HEr = High Temperature Error.

• Grill internal temperature has exceeded 287ºC (and is still hot)
  • Turn to OFF
  • Open the grill lid then turn to SMOKE. Wait to confirm that fire has been established.
  • Wait until the controller display has dropped below 90ºC, then close the grill lid and turn to the desired temperature.
• High temperature error can also occur in hot weather when the grill is in direct sunlight. Open the grill lid and move it into the shade to reduce the temperature.
• If HEr occurs when the grill is definitely NOT too hot, the grill temperature sensor or controller may not be functioning properly. Please contact our support team.

Grill Repair Instructions

HIGH VOLTAGE: Unplug the grill from electric power supply before completing any repairs. Only plug into power once all repairs are complete and grill is fully reassembled.

Scan for help information

• All key components can be replaced DIY by a "handy person".
• If a handy person is not available to complete the repairs, a BBQ repair shop, mechanical or electrical equipment repairer should be able to complete the work.
• Do not complete any repair work yourself unless suitably experienced and confident to do so.
• Refer to the table below for estimated time, difficulty, parts and tools required.
• How to repair videos are available on the Z Grills Australia website.

Component	Time	Difficulty	Spare Parts	Tools Required
Fuse	5 min		3A M205 Fast Blow Fuse 5 x 20mm *	Phillips head screw driver Wire snips or scissors
Temperature Sensor	20-30 min		ZG-200-TSENSOR	Phillips head screw driver Pliers or small socket/spanner set
Controller Board	20-30 min		ZG-200-CONT	Phillips head screw driver Wire snips or scissors Pliers
Fire-pot Fan	30-40 min		ZG-200-FPFAN	Phillips head screw driver Wire snips or scissors Pliers
Ignition Rod	30-40 min		ZG-SN-IROD	Phillips head screw driver Wire snips or scissors Wide Pliers or Small socket set
Auger Motor	30-40 min		ZG-AMOTOR-1.6	Phillips head screw driver Wire snips or scissors Pliers 7/16" Allen key

* This is a standard type of fuse widely available from electrical suppliers and retailers.

Questions?

• Submit aproduct support requeston our website. (BEST OPTION)
• Contact Z Grills Australia customer support atsupport@zgrills.com.au

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IMPORTANT SAFETY INFORMATION

• FLAMMABLE LIQUIDS: Never use or store flammable liquids near the grill, or use flammable liquids to light the grill.
• OUTDOOR USE ONLY: Do not operate the grill indoors or in enclosed spaces as carbon-monoxide poisoning may occur. The grill may be used in an open air deck or balcony as long as SAFE DISTANCE guidelines are met and smoke is able to freely vent from the ceiling/roof area.
• RAINING: Do not operate outside in the rain. The electrical components are not water proof and wood pellets must not be exposed to water.
• HIGH VOLTAGE ELECTRICITY: Plug the grill into an earthed 240V AC power supply that has safety switch protection. An extension cable can be used.
• DISCONNECT POWER: Always disconnect the power supply (unplug) before repairing the grill.

• FOLLOW INSTRUCTIONS: Assemble and use this grill ONLY in accordance with the instructions in this manual.
• SAFE DISTANCE: Ensure the grill has a MINIMUM of 1m overhead clearance and 0.3m side/rear clearance from any wall or combustible material.
• HOT SURFACES: This grill will be extremely hot during operation and for some time after turning off. Take care to avoid burns. Use heat resistant gloves.
• CHILDREN: Never leave the grill unattended when young children are present.

• PELLET STORAGE: Always store wood pellets in a dry location, away from heat or ignition sources. The wood pellets will expand, break apart and even jam the auger feed system if they get wet or are exposed to high humidity. Store pellets in air tight containers and only pour as much as required for your cook into the hopper.
• PELLET TYPE: Only use wood pellets which are made specifically for pellet grills and no larger than 6mm in diameter.
• CLEANING: Keep the grill clean in line with the instructions in this manual. A dirty grill can result in dangerous grease fires or a fire-out situation.
• FLAT SURFACE: The grill must be positioned on a flat surface for safe and clean operation.