Cook Shack 160 Installation Manual

1.800.423.0698 www.cookshack.com [e-mail]

Cookshack, Inc.

OPERATOR'S
MANUAL

Models 150 & 160
SmartSmoker® Oven

Version 07.1

Model 150 & 160

Serial No: ___________

Cookshack Model 150/160 SmartSmoker Oven 1 Ver. 07.1

1.800.423.0698 www.cookshack.com [e-mail]

Dear Cookshack Customer:

Your Model 150 /160Cookshack SmartSmoker® oven will produce great barbecue and smoked foods. It is
easy to operate, clean, and maintain. Use this Operator's Manual to familiarize yourself with the smoker and
its operation. If you have a question or problem not covered in the book, call us at 1.800.423.0698 Monday
through Friday, 9am to 4 pm or e-mail us at [e-mail]. You can also join the Cookshack Bar be-
cue Forum on our website at www.cookshack.com which has h igh pa rt icipa tion by both C ookshack cu stom­ers and staff.

You must observe safe operating practices when using the smoker. It is an electrical applia nce,
and is therefore potentiall y da nger ous! Cookshack, Inc., assumes no re sponsibilit y for r esults of
careless and dangero u s op er ation of Cookshack smoker s or other product s. All warrant ies are
null and void if the practices described in the Operato r 's Manual are not observed.

Read the following instructions thoroughly and completely before using your smoker!! Observe the in­structions careful l y. Be cert ain that you understand completely how it operates befor e att empt ing to operate
it.

This smoker oven is intended for use as a food smoker. It generates heat from an electric heating element. It
is not intende d for any use not s pec ifical ly described in this manual. Misuse of this smoker can re s ult in se­rious injury and a fire hazard.

With those cautions in mind, enjoy your smoker and the delicious foods it will produce.

The Folks at Coo kshack

Sales & Customer Service: 580-765-3669

Toll Free Orders: 800-423-0698

24 Hr. Fax: [phone]

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TABLE OF CONTENTS

Cookshack SmartSmoker® Oven

Model 150 and 16 0

Version 07.1

SETTING UP

Choosing a Location..............................................................................................................4

Ventilation.............................................................................................................................4

Electrical Power Connections................................................................................................4

COOKING

Seasoning of Oven.................................................................................................................5

Wood Selection.....................................................................................................................5

Preparing the Oven for Cooking ............................................................................................6

Smoker Oven Maximum Load Capacity................................................................................7

Loading the Oven With Meat.................................................................................................7

Setting the Cooking Temperature...........................................................................................8

Holding ............................................................................................................................... 10

SHUTDOWN PROCEDURE

Safety First.......................................................................................................................... 10

CLEANUP

Procedures ...........................................................................................................................11

MAINTENANCE

Procedures ...........................................................................................................................12

Troubleshooting Guide

Operation.............................................................................................................................13

Cooking...............................................................................................................................14

APPENDICES

A. Two Year Limited Warranty...........................................................................................15

B. Warranty Procedures.......................................................................................................16

C. Wiring Diagram..............................................................................................................17

D. Smoker Oven Illustration................................................................................................18

E. National Service Policy...................................................................................................19

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SETTING UP

Choosing a Location

Your smoker must be operated inside. Placement should be convenient to rest of cooking operation, and near
adequate ventilation, wiring connection, and clearance from flammable materials.

Do not place flammable or combust ible mater ials o n or adjacent to the smoker.

Ventilation

A small amount of smoke will escape from the vent hole in the top of the oven, and from around the door. The
oven should be placed under a hood or near a door or window with an outside exhaust.

A simple w all vent fan is a dequ ate in ma ny locations. Fa s ten no p ipes t o ove n vent.
An optional vent hood for your smoker is available from COOKSHACK. The stainless steel Smokehood

incorporates a removable grease filter a nd an exhaust fan. It mounts directly on top of the smoker and removes
the smoke vented during normal operation.

Electrical Power Connections

WARNING: All warranties are null and vo id if the insta llation of the power receptacle is not

COOKSHACK Models 150/160 have a single burner system using 120V AC power. Connect these ovens to the
power supply by plugging the power cord into a 120V receptacle which is protected by a breaker or fuse rat ed at
15 amperes.

A long or light-duty extensio n c or d will r e duce t he eff icie ncy of the heating element and food will take longer

to cook.

done in strict compliance with t hese instructions, NEMA codes, and any other applicable elec­trical codes.

Note: Due to the expense of this equipment and the risk of damage to the electrical system
contained within this equipment, insta llat ion of power r eceptacles should be done only by a
qualified electrician.

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COOKING

Seasoning of Oven

The interior of your oven should be "broken in" or seasoned before you cook your first load of meat. Place no
more than 6 ounces of wood (see Wood Selection, below) in the Wood Box. Close and latch the oven door.

(NOTE: The oven door will be hard to close. Use of both hands may be required. This is n ecess ary in order
to obtain a good seal.) Set temperature to 200°F - 225°F and turn the smoker on. Let the o ven smoke, without

meat, for a minimum of four hours. Further seasoning will occur as you cook in the oven.
Don't be alarmed if the oven temperatur e climbs somew hat hig her than the setting. That is normal. When oven is

loaded, the meat will absorb the extr a heat .

Wood Selection

You may use any fruit or nut hardwood in your smoker, as long as it has good flavoring abilities. The most popu­lar woods for smoking are hickor y, mesquite and apple. Any of these will work in your smoker and are available
from Cookshack.

Other regional favorites are alder, beech, cherry, apple, pecan, maple, o ak, buttonwood, and mangrove. Use local
woods only if logs are selected and sized pro per ly and if you are satisfied with their flavoring abilities.

Caution: the maximum amount of wood to be used in your Cookshack Model 150/160 smoker
oven is 6 ounces. Do not overload Wood Box.

Use only dry wood. You will get the best results in finished product with dry wood. Wet wood will release acids
that may damage heating elements and reduce the length of their life.

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Preparing the Oven for Cooking

CAUTION - Operation of a dirty oven may create a fire hazard. Do not allow debris to
accumulate in oven interior or on oven grills. Such debris may create a fire hazard! Fol­low all shutdown and cleaning instructions carefully.

1. Check that the Wood Box Housing is placed over the Heating Element and pushed all the way to the back
of the oven. Place properly loaded Wood Box in oven as shown. Do not remove the Wood Box fro m the
oven bottom during cooking cycle.

2. Line the bottom of the oven with aluminum foil and
punch a hole in the foil corresponding to the drain
hole. Cover the Deflector with foil for easy cleaning.
Discard the foil after each cooking and replace with

DEFLECTOR

fres h foil.

3. Place drain pan beneath the drain holes located in oven

WOOD BOX HOUSING

WOOD BOX

bottom and in the trough at bottom front of the smoker.
This drip pan should be emptied after each cooking.

4. Notice that the grills in your smoker can be rearranged
to accommodate differe nt sizes of meat.

HEATING ELEMEN T

5. When smok ing t hick ite ms, such as t u r keys o r large
hams, remove alte rnate g rills.

6. When hang-smoking ribs, remove all except the top and bottom grills, and raise side racks to highest
position.

IMPORTANT! Do not operate oven without Wood Box Housing and Wood Box in proper position.

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Smoker Oven Maximum Load Capacity

The following chart shows maximu m coo king capacities, per load, of your Cook shack smoker oven. Capacities
are based on 3 lb. ribs, 8 - 10 lbs. heavy cuts, and 3 lb. chickens. Capacities are specifically limited by the
amount of heat available.

IMPORTANT: Do not overload your smoker. Use t he S moker Oven Maximum Load Capacity
chart below to determine the maximum capacity of your smoker.

Model Lbs. Lbs. Lbs. Each Lbs

150/160 50 100 120 20 12

1. Keep meat approximately 1" away from the back and side oven walls at all times.

2. Arrange meat with fewer cuts on lower grills. Heavy loading of bottom grills will block heat and prevent
smoke from traveling to the top of the oven. This will result in undercooked meat on upper grills.
(Allowances are made for load ing arrangements when oven capacities are calculated.)

3. Load only half full the first time you cook, and gradually increase to a full load with successive batches.
Monitor closely to determine what cooking time and load amount produce the results you desire.

4. When possible, coo king schedule s s ho uld be arranged so that the same amount of an item is cook ed each
time. This allows full use of the auto mat ic operation of the oven; it will save time; a better and more
consistent product will be o bta ined.

5. When the oven is loaded according to above instr uct ions, close and latch the ove n door. Fast en t he door
latches securely. (NOTE: The door will be hard to close. This is normal.)

Ribs Brisket Pork Butt Chickens Jerky

Loading the Oven with Meat

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Setting the Cooking Temperature

Your Cookshack Model 150/160 has the new Cookshack IQ3 control system. This controller has the same great
cook & hold features as the previous models of the IQ controller, but with an addit iona l featur e that allows you to
cook with a meat probe. This optional probe plugs into the unit and allows you to set t he internal temperature to
which you want the product cooked. If you did not purchase the meat probe with your unit, call Cookshack Cus­tomer Service at [phone] to order your probe.

Directions f or u sin g the C ontroller

1. Turn Master Switch ON.

2. Choose the desired mode by pressing the MODE button while si­multaneously pushing the up or down arrow until the desired mode
flashes: Cook Mode for standard operation, which automatically
drops into the preset hold te mperatur e after t he preset cooking time
is reached; Probe Mode if cooking with the optional meat probe.
The default mode is Cook Mode.

3. Set cooking temperature by pressing and holding the COOK TEMP
button while using the ADJUST TIME OR TEMP buttons to
change settings.

4. Set holding temperature by pressing and holding the HOLD TEMP
button while using the ADJUST TIME OR TEMP buttons to
change settings.

5. If using the Cook Mode, set cooking time by pressing and holding
the COOK TIME button while using the ADJUST TIME OR
TEMP buttons to change settings.

6. If using the Probe Mode, set probe temperature by pressing and holding the PROBE TEMP button while using
the ADJUST TIME OR TEMP buttons to change settings.

7. Press START.

IMPORTANT! Close the oven door using all latches when the oven is on. Failure to close door may result
in release of large amounts of smoke and may result in smoke damage to your building.

To use the meat probe, simply insert t he jack into the covered RC A receptacle on the controller panel. Place the
probe end through the vent hole on the oven top and press into the largest piece of meat in the smoker oven. T he
oven will cook at the set cooking temperat ur e until the internal te mperatur e of the meat reache s the temperature at
which the probe is set. At that point the controller w ill change to t he set holding te mperatur e and remain there unt il
the unit is manually shut down. An audible signal indicates t hat the coo k cycle is complete and that t he oven is go­ing to the Hold Temperature Mode.

If cooking in the default Cook Mode the smoker will cook t he product at the selected cooking temperat ure for the
selected cooking time and then change to the selected holding temperature until it is shut off manually.

During both modes o f cooking the LCD display of the IQ continually displays ove n status after t he coo k cycle has
been started. Us ing these featur es any k itc he n st aff can easil y determine the stat us of the load in progress.

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Please note that the oven temperature displayed while the oven is running is the actual air temperature
inside the oven. The probe temperature displayed is the internal temperature of the product. In order to
see the set cooking temperature, probe temperature, or holding temperature, briefly press the correspond­ing button.

The IQ controller is equipped with two preset buttons for easy selection of common settings for popular
foods. Pressing the button marked Ribs/Chickens will make the following settings:

Cook Temp 225°F
Hold Temp 140°F
Cook Time 3 hours
Pressing the button marked Briskets will make the following settings:
Cook Temp 225°F
Hold Temp 140°F
Cook Time 12 hours
Once one of these preset buttons has been pushed you may start a Cook cycle using these settings by sim-

ply pressing Start.

The IQ controller is equipped with a power backup system to prevent your Smoker from ‘forgett ing’ what it is
doing in the case of a power failure. The IQ will wait out power failures of up to 2 minutes and resume normal
cooking. This backup system means that turning off the Master Switch will not cause the IQ to forget its current
instructions. The reset button may be used to clear these curr ent instructions and cause the IQ to start over from
the beginning.

Recommended cooking times and temperatures are based on full loads with no holding cycle. Larger or
smaller loads or the addition of holding time may require adjustment of cooking time and temperature.

When you think the product is finished, turn the switch to the OFF position. Wait ten minutes before
opening the oven door to check the product for doneness. When the product is done to your satisfaction,
remove from the smoker

.

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Holding

Meat should always be wrapped or sealed immediately upon removal from your smoker, and held this way until
ready to serve.

To minimize the danger of food becoming cont aminated, follow a few key steps.
The most important step is hand washing. Employees can easily transmit germs to clean food if they don't

follow basic personal hygiene. It is very important to wash after touching raw meat, fish, poultry, or dirty
utensils.

Refrigerated cases shou ld keep food at 38°F or below. Hot display cases should keep food above 140°F.
Some microor ganisms, which ca n cause d isease when present in low numbers, don't require temperature abuse

to be dangerous. To avo id these disea ses, exclude infected perso nnel from foodservice operations, use clean
utensils when handling food, practice clean persona l hygiene, and use the pro per containers when covering
food.

Remember, these are bas ic gu ideline s only and are not intended to replace laws, regulations, or restrictions
concerning the handling and processing of food products. For further information, use your local health
department guidelines to determine the best method for holding product, hot or cold.

SHUTDOWN PROCEDURE

Safety Firs t

1. Turn On/Off switch to OFF position.

2. Wait at least 10 minutes before opening door.

3. Open door slowly. This allows the wood and element to cool sufficiently so that a fire will not occur
when the cold air rushes into the oven.

4. IMPORTANT!! If oven is to be left unattended with the door open remove the Wood Box from the

oven using the wood box handle and douse the contents with water.

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CLEANUP

FAILURE TO FOLLOW THESE INSTRUCTI ONS MAY RES ULT IN A FIRE HAZARD!

Procedures

Always disconnect the oven from its electrical supply before cleaning or servicing.

Your Cookshack smoker must be kept clean. Loose grease and scale should be removed regularly to prevent
buildup, which may cause strong fumes. It is desirable to allow seasoned coating, such as that found on a
well-seasoned ca st iron skillet, to remain on the o ven walls. Fo r t h is reason we do not recommend
attempting to restore the oven walls to a "like new" stat e after each coo king. The use o f deter gent , chemical
cleaners, or "oven cleaner" is not advised.

IMPORTANT: Caustic oven cleaners may damage heating element and grills. Use of oven clean­ers or other caustic cleaners will void the warranty on heating element and grills.

Follow this procedure after each load:

1. Disconnect oven from power supply.

2. Allow the oven to cool.

3. Remove the grills and racks; scrape and wash with soap and water.

4. Empty Wood Box. (Remember it's hot!) Use the Wood Box handle supplied with oven.

5. Discard aluminum foil.

6. Remove all grease from inter ior o f oven.

7. Empty drip pan.

8. Leave door slightly ajar when oven is not in use.

9. Refer to safety precautions above.

10. Replace Wood Box to correct position.

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Follow this procedure every 4—5 loads:

1. Re move g rills and rack s ; scrape and wash.

2. Empty Wood Box. (Remember it’s hot!)

3. Remov e Woodbox and bru sh c lean. (Remember it’s hot!)

4. Scrape loose grease and scale from walls with flat edge scr aper .

5. Replace racks and grills.

6. Replace Woodbo x to correct po sit ion.

IMPORTANT: Reverse the ab ove cleaning instructions after each cleaning t o re-assemble the oven cor­rectly. Do not operate oven without Heat Shield and Wood Box in proper position.

IMPORTANT: Bottom of oven must be kept clean. Change foil in bott o m of oven an d from Heat De fle c to r
after each cooking and remove all excess grease from interior of oven. Drain hole must be open at all
times. If drain becomes plugged, oven bottom can fill with grease and a fire hazard may occur!

MAINTENANCE

Procedures

1. Periodically check electrical plug and wire for any type of wear or damage.

2. Twice annually put two drops of lightweight oil on the hinge pins to prevent binding.

3. Check casters for free movement .

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TROUBLESHOOTING GUIDE

Operations

Uneven cooking Impr oper meat loa d ing See loading instructi ons

PROBLEM POSSIBLE CAUSE SOLUTION

Str ong grease fum es . “Charcoal” fl avor Excessi v ely dirty oven Clean oven per cl ean ing instructi on s

Meat sticks to lower grill Heavy “blanket” loading Load with ample room for upward pas-

sage of heat

Direct burner heat in center of grill Place foil under meat on bottom grill

Smoke coming from top of door Normal

Product gets too done on bottom grill.
Product on top grills is underdone

Although smoker i s set wi t h the same
time and temperature as always, prod­uct is now taking longer to cook

Actual oven temperature ready 5° to
20° higher or lower than the set tem­perature

Impr oper loading Load li gh ter at th e bottom for efficien t

heat an d smoke circu lation

Malfunctioning heating element Hav e electr ician ch ange element

Normal

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TROUBLESHOOTING GUIDE

Cooking

PROBLEM

Poul tr y too dark Too much wood Use l e s s wood. Poultr y a bsor bs smoke

Bitter skin on poultry Too much wood Use less wood

Fish too d a rk Too much wood Use l e s s wood

No smoke taste Not enough wood Use more wood

POSSIBLE CAUSE SOLUTION

easily so start with the minimum amount
suggested and gradually increase the
amoun t wi th successive loa d s until the
desired smoke flavor is reached.

Product too dry Oven humidity too low Increase cooking temperature and de-

creas e co ok ing time

Skin on poultry cracking Rub with vegetable oil, butter or mayon-

Fish falls through grills Overcooking. Grill spacing too large to

support fish

Ribs fall off Ri b H ooks Ribs n ot secure ly fastened Review Rib Ho ok instr uctions. Make

Overcooking Cook for shorter time

naise bef ore cooking. Us e Cooks ha ck
Water M agazine to increase ov en humid ­ity

Cook for shorter time. Use Cookshack
Seafood Grills

sure h ooks are securely in ser ted between
the top two ribs on th e slab

Poultry not getting done Overloading Review loading and capacity instructions

Load cooks u nevenly Impr op er loading Follow smoker oven loa ding instr u ction s

in O perator’s Man ual. Alwa ys load bot-

Brisket on bottom cooks too fast Improper loading Load bottom grill with fewer briskets

tom shelves lighter. Do not use sheet
pans in th e s moker. Th ey block even
circulation of heat and smoke.

and load with fat side down

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APPENDIX A

T wo Year Limited Warranty

Cookshack Smoker Ovens are guaranteed t o be free from defects in material and workmanship under nor mal
use and when installed in accordance with factory reco mmendations.
This limited warranty includes parts and labor for the first 90 days. Following the 90 day period, the two (2)
year limited warranty is for parts only.
Cookshack, Inc.’s obligation under this warranty shall be to repair and replace at its option any part deemed
defective upon examination by Cookshack, Inc., or its authorized agent, for a period of two (2) years fro m the
date of sale.
PROCEDURES

1. Customer must obtain approval from Cookshack, Inc. before performing any service. Cookshack, Inc. is
not responsible for any unauthor ized service wo r k.

2. The Limited Warranty extends to t he original purchaser o nly.

3. To make claim or request for the Limited Warranty, the o r iginal purchaser must notify Cookshack, Inc.
Customer Service for instructions as to the repair or replacement of the defect ive merchandise prior to
attempting or contracting for repair of the oven.

4. The Limited Warranty shall not apply if the merchandise has been improperly installed, damaged due to
abuse, misuse, misapplication, accident, or as a resu lt of service o r modification by any other than an
authorized Coo kshack, I nc. ser v ice agent .

5. There are no express warranties other than the limited warranty stated herein above. No warranties
whether express or implied, including, but not limited to, any implied warranties of merchantability of
fitness for a particular purpose, shall extend beyond the respect ive warrant y periods described above.

6. Cookshack, Inc. shall not be liable for any direct, indirect, special, consequentia l, incident al, or punitive
damages; lost profits or loss of use or interruption of business regardless of the form of action or theory
of liability resulting from any defect in or use of the Cookshack smoker oven, accessor ies and/or heating
elements.

Additional information on obtaining service under this Limited Warranty is available on the following page or
by contacting a Cookshack, Inc. Customer Service Representative direct ly at [phone].

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APPENDIX B

Warranty Procedures

If you have merchand ise that you belie ve is d efec tive, or want to return bas ed on Cooksha ck’s 30 D ay Money
Back Guarantee, please call Cookshack, Inc., at [phone] and ask to speak to a Customer Service Repre­sentative (CSR). Have your smoker oven model and serial number available, if applicable. T he CSR will take the
information you provide and make a determination regar ding the solut ion to the problem. It is Cookshack, I nc.’s,
option whether to replace or repair defective merchandise. I f you are told that your merchandise will be repaired
or replaced under warranty, the following actions will be initiated:

1. The CSR will issue a Return Merchandise Authorization (RMA). This author izat ion is assigned a nu mber
which is used to track the merchandise being returned. P lease do not r etur n any merchandise to Cookshack,
Inc. wit hout first obtain ing this authoriza tion and R MA nu mber. To do so will dela y the a ppropriate r e s olution
of the issue(s) in question. In some cases the CSR may mail you a for m with an RMA number included. This
form will ask you to detail why it is felt that t he merchandise needs to be repa ired, replaced or retur ned. T his
merchandise much be received by Coo k shack, Inc. within 30 days of the issue dat e of the RMA.

2. Package the merchandise in its original packaging, if poss ible. If this is not feasible, use equivalent packaging
to ensure the safe retur n of the items. You assume the risk of any loss or damage that occur s during transit due
to improper packaging of the merchandise being returned.

3. Using a permanent magic marker clearly write t he RMA number o n t he out side of the packaging. This enables
personnel in Receiving to identify the merchandise and initiate the repa ir or replacement procedures authorized
by the CSR.

4. Ship the merchandise to Cookshack, Inc., 2304 N. Ash St., Ponca City, OK 74601, shipping prepaid, F.O.B.
destination. At the discretion of the CSR, Cookshack, Inc. may issue a UPS Call Tag. I n this case the return
freight will be paid by Cookshack. .

5. In some cases, at Cookshack Inc.’s option, replacement merchandise may be shipped to you prior to our re­ceipt of the defective merchandise. I n t h is instance you will be invoiced for t he replacement merchandise upon
shipment. Credit for this charge will be issued to yo u upon our receipt o f the defective product.

6. Credit may be denied

if the returned merchandise is not found to be defective by Cookshack, Inc.; if it is not
under warranty; if it is not received at Cookshack, Inc. 30 days after the RMA is issued; if it is damaged due to
abuse, misuse, misapplication, or accident; if it has been serviced or modified by any other than an authorized
Cookshack, Inc. servic e agent ; is not returned with an RMA number; is not in clean co ndition; is not complete;
is damaged or lost in transit. Inspection performed upon receipt of the product can override the initial decision
regarding repair or replacement made by the CSR.

7. Replacement merchandise is sent to you via UPS Ground or common carrier. If you request replacement mer­chandise be sent by faster ser v ice t han UPS Ground or common carrier you shall incur t he co st of shipping in
excess o f nor mal gro und service.

8. If this return is based on Cookshack’s 30 Da y Money Back Guarantee call Cook shack, I nc. and fo llow steps 1
through 3 above. The customer must ship the unit back prepaid.

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APPENDIX C

Wiring Diagram

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APPENDIX D

Smoker Oven Illustration

PV696-MASTER ON/OFF SWITCH

PV535-MEAT PROBE RECEPTACLE
PV536-COVER MEAT PROBE RECEPTACLE

INSIDE ELECTRICAL COVER

PV625-TRANSFORMER

PV682-RELAY

PA122-HANDLE ASSEMBLY
& MAGNET

PV683-HEAT SINK

PV532-MEAT PROBE, OPTIONAL

NOT SHOWN

GREASE DEFLECTOR

LA306-LABEL, MADE IN USA

PV684-IQ4 CONTROL BOARD

PV146 VENT (SM076)
PV145 VENT (SM075)

PA124-HALL SENSOR SWITCH

PV169 DOOR LATCH (SM076)
PV168 DOOR LATCH (SM075)

PV011-GRILL

PM023-GRILL SIDE RACK

PV718-TEMPERATURE SE NSO R

PV551-HI-LIM I T THERMO S TA T

HEAT DEFLECTOR

PM304-WOODBOX HOUSING

PM305-WOODBOX HOUSING

PM324-HEATING ELEMENT

PV170-SWIVEL CASTER, BACK
PV171-BRAKE CASTER, FRONT

PV701-DRIP PAN

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APPENDIX E

National Service Policy

Cookshack, Inc., National Service Policy is to build quality equipment with eas y serviceability. Because of the
ease of serviceabilit y, Co okshack does not have Nat ional Serv ice Companies to repair their equipment. This
allows each rest aur ant to use the service company of their cho ice.

If your unit needs repairs, please contact your preferred local service company. If warranty work is deemed
necessary, equipment owners should have their local service company contact Cookshack, Inc. at 580-765­3669 for authorization to perform the repairs.

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