Remove and Install New DCS Infrared Rotisserie Burner, Orifice, Elbow.

by grillrepair on April 13, 2014

Majestic Grill Parts Instructions to remove the infrared rotisserie burner in a DCS (Dynamic Cooking Systems) barbecue grill.  The model we are working with here is a BGA-27 which means the grill has stainless steel burners and 9.5 inch porcelain radiant rods above the burners and below the grilling grates.

Many of the steps here are the same to access the rotisserie burner orifice when we need to convert the rotisserie to burn natural gas from propane or from propane to natural gas.

Front of rotisserie burner in DCS BBQ grill.

Front of rotisserie burner in DCS BBQ grill. This burner will be very tight after 10 years of use and is not usually easy to remove.

The rotisserie burner is the infrared back burner in the vertical back wall of the grill.  Although inexpensive appliances made in Asia are calling all sorts of things “infrared” the true, original definition of an infrared burner is a burner that has a thick casing to allow gas to build up until the gas escapes through a ceramic tile with thousands of small flame ports.  By the time the housing is full of gas, the gas is under enough pressure to force the gas through thousands of ports which makes each flame much, much hotter than what we expect from our natural gas and propane appliances.

Sometimes the stainless casing will rust holes (which takes a very long time) and sometimes the ceramic will be cracked.  In either case we’ll need to replace the infrared rotisserie burner.

Back Stainless Panels on DCS 27 barbecue grill model

Back Stainless Panels on DCS 27 barbecue grill model must be removed to get at the rotisserie burner, thermocouple, electrode and gas line attachment.

This particular DCS model has a lower panel and an upper panel fabricated of 304 stainless steel.  Removing the panels is very simple since there are obvious screws holding the panels in place.

 

 

 

 

 

 

 

DCS back panel screws along edge can be removed

DCS back panel screws along edge can be removed; even after many years of rust these are not usually difficult to unscrew.

As the caption says the screws in the back of this 10 year old DCS were badly rusted and were very tight because of the swelling from oxidation but they all came free of the back panels without needing to be drilled or cut.

Any of us who have worked on these amazingly well-built grills knows it is not uncommon to have to drill or cut the screws holding the electrodes and collector boxes inside the grill.  The outside screws are not going to last forever but after ten years the threads held true.

Removing the back stainless panels on the DCS BBQ grill.

Removing the back stainless panels on the DCS BBQ grill. Each panel is bent to hook to the inner structure

We removed the upper panel first and then the lower panel.  With the upper panel removed we are able to see the installation of the rotisserie burner and we can see the gas pipe connecting to the rotisserie burner.

The control valve for the rotisserie burner is the same control valve as the other DCS burners except the tip of the valve where there is usually a gas orifice has a small gas line attached.  This aluminum gas line attaches the valve to the safety valve which we only see from outside the control panel as a button.  The safety valve has a spring-loaded solenoid that interrupts the flow of gas unless the button is depressed.  We ignite the grill rotisserie burner while holding the button down so gas will flow.  Once the infrared rotisserie burner ignites the heat from the infrared flames will heat the tip of the thermocouple which creates a electromagnet that holds the solenoid compressed.

In this way the heat from the burner keeps the gas flowing through the safer valve.  If the burner goes out for any reason the solenoid closes to stop the flow of gas to the vertical rotisserie burner.  We aluminum gas pipe connects from the safety valve button all the way back to the infrared burner.  The rotisserie burner attaches to the gas line with the use of a elbow adaptor.

The elbow adaptor has a compression fitting on the bottom so the gas line is sealed into the elbow.  After the nine degree bend there are 2 sets of threads so the elbow can be strongly mounted to the burner and so a orifice can be attached inside the burner to regulate the flow of gas to the particular BTU setting for the burner.

 

old dcs rotisserie mounting screw and rusted through to infrared tile

This old infrared rotisserie burner casing has rusted so badly the ceramic tiles are visible through the back of the burner. The screw on the right side is one of two mounting screws.

There are only two bolts holding the DCS rotisserie burner in place.  Although these are much smaller and rusted badly, again they were tight but came out easily with a drill.

This image shows the far side of the burner, opposite the gas line connection.  On this side of the burner the electrode is passed through the wall of the grill.  Inside the barbecue there is a stainless cover that covers the igniter.

As we can see in this image our rotisserie burner has rusted through badly.  From the back of the burner we can see through the stainless steel into the ceramic tiles in the front of the rotisserie burner.

DCS rotisserie mounting screw, elbow connection and gas orifice.

The Orifice attaches to the elbow which is connected the gas gas line to the rotisserie burner. Behind the orifice is the second of two mounting screws

Behond the gas orifice for the infrared DCS rotisserie burner we can see the second mounting screw.  There are only 2 screws holding the burner to the back wall of the grill.  The first mounting screw was on the far left where the electrode passes through the wall next to the end of the burner.  The second screw is behind the orifice.

I apologize I do not have a better way to do this but I used a long screwdriver at an angle and worked very slowly pressing against the screw very hard — if we strip this old rusted screw-head we’ll have to drill it out.  We could also use a drill with an extra long phillips head bit at an angle but we need to be able to apply forward pressure and move slowly to minimize the possibility of damaging the screw head.   We removed the orifice with an open-ended wrench which allowed for a little extra room.

Rotisserie elbow installed in DCS grill with hood valve.

The elbow with male threads uses the same brass gas office as the DCS control valves. This image shows the gas pipe, elbow orifice and infrared burner installed.

Once the second screw has been removed we can remove the burner.  We should — determine the condition of your grill parts and materials — remove the elbow first to make sure we do not damage the aluminum gas line when we pull out the burner.

However, let’s look at the grill part assembly without ten years of grease, carbon deposits, dirt and rust.  This image shows the aluminum gas line coming up from the controls in the front of the DCS barbecue.  The compression fitting at the bottom of the elbow seals to the gas line with a soft brass ferrel that is crushed when the nut tightens to the elbow while the aluminum is pressed inside the opening.  The soft brass ferrel gets compressed to seal around the aluminum so there is no possibility of a gas leak.

DCS has two different versions of the rotisserie elbow.  This one in this image uses the saml physical hood orifice as the control valves in the front of the grill.   Past the 90 degree bend of the elbow, above the compression nut,  the adaptor is threaded so a single large brass nut holds the elbow to the rotisserie.  Past that mounting nut is another, smaller threaded adaptor designed to hold the orifice.

The other DCS elbow is machined for a special spud-type orifice.  Both elbow adapters mount the same and work the same so it does not matter which one we are dealing with.

Once we get to this point and we remove the orifice the next step is to remove the large nut holding the elbow to the rotisserie burner and slide the elbow away from the burner.   Please Note:  It may be necessary to use a degreaser and a wire brush to loosen a decade of rust and corrosion to remove the elbow without damaging  anything.   Please examine the parts, use a large open-ended wrench on the large nut and if the nut is not able to break free and thread off the elbow, start using the degreasers and brush at the rust to free the fitting so we do not damage anything.  The orifice, elbow, aluminum gas piping and the infrared rotisserie burner can all be replaced but since we’re either going through this process to replace the rotisserie burner or to replace the rotisserie orifice we can avoid replacing more parts by paying attention to the condition of the venturi bracket and adapter.

Front of rotisserie burner in DCS BBQ grill.

Front of rotisserie burner in DCS BBQ grill. This burner will be very tight after 10 years of use and is not usually easy to remove.

We realize we have already shown this particular image.  We’re showing it again because it is now time to remove the rotisserie burner.  It is very common for the rotisserie burner to seem completely free of the two mounting bolts used to install the burner yet the burner will still not come loose from its framing.  With a decade of heating and cooling, expanding and contracting and a bit of grease, carbon deposits from flames and oxidation it is common for the burner to be held tightly in the framed opening in the back of the grill.

When we cannot gently pry the burner out, side by side we’ll usually use a thick wash-cloth folded up and pressed against the stainless frame and then place a scraper blade or a screwdriver on the rags so we can tap on the screwdriver or paint scraper.  This will eventually move the frame with its ceramic tiles left undamaged.

Use cardboard or rags to cushion the point of impact and also spread the pressure of lightly hitting the ceramic with a mallet.  This will press the rotisserie burner from the tight stainless framing.

 

DCS rotisserie gas line elbow connection installs to rotisserie burner with orifice.

This DCS elbow connection has female threads for the orifice but installs to the gas line rotisserie exactly the same as the other DCS rotisserie elbow.

Once the old rotisserie burner is out we can install the new infrared burner.  we’ll need to install the elbow and the orifice with the aluminum gas line.   This image shows the other version of the elbow adaptor used in rotisserie burner   installation.  The elbow above has the same hood orifice as the control valves that feed gas to the main barbecue burners.  The other version of the DCS elbow is mostly the same and installs the same but it does use a different orifice as shown in these images.

Spud rotisserie orifice installed in elbow adaptor in burner.

Elbow adaptor is bolted to the infrared rotisserie venturi and has spud orifice screwed into elbow as installed in the DCS grill.

This second image shows the DCS adaptor elbow with the spud orifice installed.  Both versions of the DCS elbow will connect the the aluminum gas pipe and both orifices are short of the intake tube feeding gas into the infrared burner so both cause oxygen to mix with gas as the gas pressurizes inside the infrared burner housing.

back side of new infrared rotisserie installed in DCS BGA 27 BQRL

Although removing the 20 year old burner can be tough the new rotisserie burner will slide easily into the opening and then the same 2 screws hold the burner in the grill.

Whether we install the burner before installing the elbow or install the elbow and then mount the rotisserie to the back wall of the grill at this point we are installing our new infrared rotisserie burner.

This DCS BGA-27 is over a decade old and the owners did not treat the barbecue grill especially well — but then most of us don’t.  The new burner makes the rest of the grill look even more greasy, dirty and rusty than it looked with the old rusted and broken rotisserie burner.

At least this one is going to work!

DCS BGA-27 BQRL with newly installed infrared rotisserie burner.

Front view of newly installed rotisserie burner makes the rest of the grill look pretty rough.

The replacement DCS infrared rotisserie burners can be viewed and purchased from the

DCS Rotisserie Burners page.

This page has replacement elbow adaptors, orifices, gas pipes and other

DCS BBQ Grill Parts available.

For additional information, Please contact Majestic Grill Parts at:

Service@Grill-Repair.com

954-2-GRILL-2. which is also: 954.247.4552.

http://www.facebook.com/grillrepair

http://www.grill-repair.com

 

 

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