Cookshack SmartSmoker 150, SmartSmoker 160 Operator's Manual

1.800.423.0698 www.cookshack.com [e-mail]

Cookshack, Inc.

OPERATOR'S
MANUAL

Models 150 & 160
SmartSmoker® Oven

Version 06.1

Model 150 & 160

Serial No: ___________

Cookshack Model 150/160 SmartSmoker Oven 1 Ver. 06.1

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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 Barbe-
cue Forum on our website at www.cookshack.com which has high participation by both Cookshack custom­ers and staff.

You must observe safe operating practices when using the smoker. It is an electrical appliance,
and is therefore potentially dangerous! Cookshack, Inc., assumes no responsibility for results of
careless and dangerous operation of Cookshack smokers or other products. All warranties are
null and void if the practices described in the Operator's Manual are not observed.

Read the following instructions thoroughly and completely before using your smoker!! Observe the in­structions carefully. Be certain that you understand completely how it operates before attempting 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 intended for any use not specifically described in this manual. Misuse of this smoker can result 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 Cookshack

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 160

Version 06.1

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 ......................................................................................................................................11

CLEANUP

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

MAINTENANCE

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

TROUBLESHOOTING GUIDE

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

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

APPENDICES

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

B. Return Merchandise Policy................................................................................................................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 combustible materials on 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 wall vent fan is adequate in many locations. Fasten no pipes to oven vent.

An optional vent hood for your smoker is available from COOKSHACK. The stainless steel Smokehood
incorporates a removable grease filter and 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 void if the installation of the power receptacle is not
done in strict compliance with these instructions, NEMA codes, and any other applicable elec­trical codes.

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
rated at 15 amperes.

Note: Due to the expense of this equipment and the risk of damage to the electrical system
contained within this equipment, installation of power receptacles should be done only by a
qualified electrician.

A long or light-duty extension cord will reduce the efficiency of the heating element and food will take

longer to cook.

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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. Set temperature to 200°F - 225°F and turn the smoker on. Let the oven 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 temperature climbs somewhat higher than the setting. That is normal. When
oven is loaded, the meat will absorb the extra 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 hickory, 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, oak, buttonwood, and mangrove.
Use local woods only if logs are selected and sized properly and if you are satisfied with their flavoring
abilities.

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.

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.

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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 from 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 fresh foil.

3. Place drain pan beneath the drain holes located in oven
bottom and in the trough at bottom front of the smoker.
This drip pan should be emptied after each cooking.

WOOD BOX HOUSING

WOOD BOX

DEFLECTOR

HEATING ELEMEN T

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

5. When smoking thick items, such as turkeys or large hams, remove alternate grills.

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

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

The following chart shows maximum cooking capacities, per load, of your Cookshack 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.

Model Lbs. Lbs. Lbs. Each Lbs

150/160 50 100 120 20 12

Ribs Brisket Pork Butt Chickens Jerky

Loading the Oven with Meat

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 loading 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, cooking schedules should be arranged so that the same amount of an item is cooked each
time. This allows full use of the automatic operation of the oven; it will save time; a better and more
consistent product will be obtained.

5. When the oven is loaded according to above instructions, close and latch the oven door. Fasten the door
latches securely.

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Setting the Cooking Temperature

Your Cookshack Model 150 and 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 additional feature that al­lows you to cook with a meat probe. This optional probe plugs into the unit and allows you to set the internal
temperature to which you want the product cooked. If you did not purchase the meat probe with your unit, call
Cookshack Customer Service today at [phone] to order your probe.

1. Turn Master Switch ON.

2. Choose the desired mode by pressing the mode button
while simultaneously pushing the up or down arrow: Cook
Mode for standard operation, Probe Mode if cooking with
the optional meat probe. The default mode is Cook &
Hold.

3. Set Cooking temperature by pressing and holding the
Cook Temp button. Adjust temperature up or down with
the “adjust time or temperature” buttons.

4. Set Hold temperature by pressing and holding the Hold
temperature button. Adjust with the “adjust time or tem­perature” buttons.

5. If using the Cook & Hold mode, set Cook Time by press­ing and holding the Cook Time button. Adjust with the
“adjust time or temperature” buttons.

6. If using the Probe Mode, adjust Probe Temperature by
pressing and Holding the Probe button. Adjust the tem­perature with the “adjust time or temperature” buttons.

7. Press Start.

If using the Meat Probe, simply insert the probe into the covered
RCA jack. Place the probe end through the vent hole on the oven top and press into the largest piece of meat in
the smoker oven. The oven will cook at the set temperature, until the internal temperature of the meat hits the
temperature at which the probe is set. At that point the oven temperature will change to the set Hold Temp and
remain until the unit is manually shut down. An audible signal indicates that the Cook cycle is complete and
that the oven is going to the Hold Temperature.

If cooking in the default Cook & Hold mode the smoker will cook the product at the selected Cook Tempera­ture for the selected Cook Time and then change to the selected Hold Temperature until it is shut off manually.

During the Cook & Hold mode, the LCD display of the IQ continually displays oven status after the Cook cy­cle has been started. Using these features any kitchen staff can easily determine the status of the load in pro­gress.

Please note that the Oven Temperature that is displayed while the oven is running is the actual temperature in­side the oven. In order to see the Set Cook Temp, Hold Temp or Cook Time briefly press the corresponding
Set button.

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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 simply

pressing Start.

The IQ controller is equipped with a power backup system to prevent your Smoker from ‘forgetting’ 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 current instructions and cause the IQ to start
over from the beginning.

The IQ controller is also equipped with a door position sensor. If the oven door is open, the controller display
reads “Door Open” and the controller beeps until the door is closed. The heating elements remain off. It is
necessary for the metal guide located at the upper right corner of the oven door to press against the sensor
button located on the upper left corner of the right side of the oven. If this metal guide is bent out of position the
oven will not operate. Please contact your Cookshack Service Representative for assistance if you experience
this problem. 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.

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.

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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 contaminated, 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 should keep food at 38°F or below. Hot display cases should keep food above 140°F.

Some microorganisms, which can cause disease when present in low numbers, don't require temperature
abuse to be dangerous. To avoid these diseases, exclude infected personnel from foodservice operations, use
clean utensils when handling food, practice clean personal hygiene, and use the proper containers when
covering food.

Remember, these are basic guidelines 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.

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SHUTDOWN PROCEDURE

Safety First

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.

CLEANUP

FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN A FIRE HAZARD!

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

Procedures

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 well­seasoned cast iron skillet, to remain on the oven walls. For this reason we do not recommend attempting to
restore the oven walls to a "like new" state after each cooking. The use of detergent, 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.

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6. Remove all grease from interior of 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.

Follow this procedure every 4 - 5 loads:

1. Remove grills and racks; scrape and wash.

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

3. Remove Wood Box Housing and brush clean. (Remember it's hot!)

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

5. Replace racks and grills.

6. Replace Wood Box Housing and Wood Box to correct position.

IMPORTANT: Reverse the above cleaning instructions after each cleaning to 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 bottom of oven and from
top of Wood Box 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 Improper meat loading See loading instructions

Strong grease fumes. “Charcoal” flavor Excessively dirty oven Clean oven per cleaning instructions

PROBLEM POSSIBLE CAUSE SOLUTION

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

Door Closed Light doesn’t come on
when door is closed

Improper loading Load lighter at the bottom for efficient

Door closed sensor in wrong position Align door sensor. Call Cookshack cus-

Although smoker is set with 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

Malfunctioning heating element Have electrician change element

Normal

heat and smoke circulation

tomer service for assistance

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TROUBLESHOOTING GUIDE

Cooking

Poultry too dark Too much wood Use less wood. Poultry absorbs smoke

PROBLEM

Bitter skin on poultry Too much wood Use less wood

POSSIBLE CAUSE SOLUTION

easily so start with the minimum amount
suggested and gradually increase the
amount with successive loads until the
desired smoke flavor is reached.

Fish too dark Too much wood Use less wood

No smoke taste Not enough wood Use more wood

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

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

crease cooking time

naise before cooking. Use Cookshack
Water Magazine to increase oven humid­ity

Fish falls through grills Overcooking. Grill spacing too large to

support fish

Ribs fall off Rib Hooks Ribs not securely fastened Review Rib Hook instructions. Make

Overcooking Cook for shorter time

Cook for shorter time. Use Cookshack
Seafood Grills

sure hooks are securely inserted between
the top two ribs on the slab

Poultry not getting done Overloading Review loading and capacity instructions

Load cooks unevenly Improper loading Follow smoker oven loading instructions

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

in Operator’s Manual. Always load bot­tom shelves lighter. Do not use sheet
pans in the smoker. They block even
circulation of heat and smoke.

and load with fat side down

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APPENDIX A

TWO YEAR LIMITED WARRANTY

Cookshack Smoker Ovens are guaranteed to be free from defects in material and workmanship under
normal use and when installed in accordance with factory recommendations.

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 from the
date of sale.

Customer must obtain approval from Cookshack, Inc. before performing any service. Cookshack, Inc. is not
responsible for any unauthorized service work.

1. The Limited Warranty extends to the original purchaser only.

2. To make claim or request for the Limited Warranty, the original purchaser must notify Cookshack, Inc.
Customer Service for instructions as to the repair or replacement of the defective merchandise prior to
attempting or contracting for repair of the oven. (See following page for Return Merchandise Policies).

3. The model number and serial number of the Cookshack Smoker Oven must accompany any request for
service to 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 result of service or modification by any other than an authorized
Cookshack, Inc. service agent.

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 respective warranty periods described above.

Cookshack, Inc. shall not be liable for any direct, indirect, special, consequential, incidental, 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, accessories 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 directly at [phone].

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APPENDIX B

RETURN MERCHANDISE POLICY

If you have merchandise that you believe is defective and requires repair or replacement:

1. Call Cookshack, Inc. at [phone]. Ask to speak to a Customer Service Representative. Have your
Smoker Oven model number and serial number ready.

2. If you are advised to return the merchandise to the factory for repair or replacement, please observe the
following procedures.

3. You will be issued a return number. A Customer Service Representative will issue you a return number
and/or mail you an instruction form (called a Return Merchandise Authorization) for returning the
merchandise with the return number on it.

4. All return merchandise must have a return number. Do not return merchandise without a return number.

5. Attach the return number to the merchandise.

6. If you were sent a Return Merchandise Authorization, attach it to the merchandise you are returning.

7. If you were issued an RETURN NUMBER by phone and not sent a Return Merchandise Authorization,
attach a note to the merchandise with your name, address and RETURN NUMBER.

8. Print the RETURN NUMBER on the outside of the return packaging.

9. Ship the merchandise back to Cookshack, Inc. 2304 N. Ash St., Ponca City, OK 74601. Shipping must
be prepaid, F.O.B. destination, in the original container or equivalent.

10. You assume the risk of any loss or damage that occurs during transit due to improper packaging of the
returned merchandise.

Repair or replacement of merchandise under warranty.

1. Replacement of or repairing defective merchandise is at Cookshack, Inc.'s option.

2. If repair of merchandise is deemed necessary by Cookshack, Inc. you will be instructed as to the
necessary arrangements in order to affect the repair of the merchandise.

3. If replacement of merchandise is deemed necessary by Cookshack, Inc. you will be invoiced for the
replacement merchandise upon shipment. Credit for merchandise under warranty deemed to be defective
by Cookshack, Inc. will be issued upon return of the defective merchandise.

4. 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 your RETURN NUMBER 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. service agent; is not returned with an
RETURN NUMBER; is not in clean condition; is not complete; is damaged or lost in transit.

5. Replacement merchandise is sent to you via UPS Ground or common carrier. If you request replacement
merchandise be sent by faster service than UPS Ground or common carrier you shall incur the cost of
shipping.

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APPENDIX C

WIRING DIAGRAM

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APPENDIX D

COOKSHACK SMARTSMOKER OVEN

PV531-MEAT PROBE, OPTIONAL

LA306-LA 306, MAD E IN USA

PV685-IQ 3 CONTROL BOA RD

PV696-MASTER ON/OFF SWITCH

PV536-MEAT PROBE JACK COVER

INSIDE ELECTRICAL COVER
PV625-TRANSFORMER
PV682-R ELAY
PV683-HEAT SINK
PV452-WIRING HARNESS

PA122-HANDLE ASSEMBLY
& MAGNET

PV535-MEAT PR OBE, JACK

NOT SHOWN

GREASE DEFLEC TOR

PV146-VENT (S M150)
PV147-VENT (S M160)

PV124-HALL SENSOR SWITCH

PV168-DOOR LATCH (SM150)
PV169-DOOR LATCH (SM160)

PV012-GR ILL

PA024-GRILL SIDE RACK

PV720-TEMPERATURE SENSOR

PV551-HI-LIM IT THERMOSTA T

HEAT DEFLECTOR

PM300-WOODBOX HOUSING

PM305-WOODBOX

PV320-HEATING ELEMENT

PV170-SWIVEL CA STER, 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 easy serviceability. Because of
the ease of serviceability, Cookshack does not have National Service Companies to repair their equipment. This
allows each restaurant to use the service company of their choice.

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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