Replace Infrared Rotisserie Burner: Instructions And Video Tutorial.

by grillrepair on November 1, 2015

Remove Replace Install Infrared Rotisserie Burner — In A DCS That Does Not Have A Removable Back Access Wall.

         Although there are  different designs for the infrared rotisserie burner and different grill designs means different ways to access and replace the rotisserie burner, the essential process is the same for each — essentially. The Video Above is taken from removing and installing a new infrared rotisserie burner in a very old DCS model DCS48-A-BQR.  The model marked “A” only existed as the designs started to change so this particular model would have been called a DCS48BQR during its own lifetime.  The “A” marks this as the first DCS — a tremendous achievement when we look back at the amazing gas grills produced over the next 25 years by Dynamic Cooking Systems and the thousands of grill models who existed by copying the DCS designs and high quality fabrication.  We are using the A model in this video and this original DCS did not have a removable back wall so the infrared rotisserie burner had to be pulled from the grill straight out from the front.  The grill is so old the bolts holding the rotisserie burner in the inner back wall are too rusted and corroded to unscrew so we are grinding them down and drilling them through and banging them free with a chisel in order to free the rotisserie burner.

infrared rotisserie cover over igniter and thermocouple

One type of burner cover for DCS infrared rotisserie burners protecting the ignitor and thermocouple safety function.

There are more than one type of ignition electrode cover which protects the ignitor electrode and thermocouple.  In this DCS48-A model the grill structure did not yet permit the back wall to be removed so the infrared rotisserie burner has to be removed from the front of the back wall inside the grill.  …from the front of the back wall… I know that’s not great writing but basically we want to grab the burner and pull it towards where we’re standing.  However, before we can grab the infrared rotisserie burner we need to remove the mounting bolts and free the gas connection which is below the igniter cover.

Remove stainless ignition cover from rotisserie burner

Stainless burner cover must be removed to remove or install infrared rotisserie burner — even if this means grinding off the bolt-heads.

This particular rotisserie ignitor cover is long and thin but DCS had 2 other versions of this same functional cover.  The cover grounded and supported the ignitor electrode and the thermocouple which generates an electromagnet inside the safety valve as part of the safety features of these original rotisserie burners.  To remove this cover and expose the incoming gas line we will remove one bolt at the top and one bolt at the bottom.  Once these are removed we will have to wiggle a bit to dislodge the thermocouple and the electrode.  Both the ignition electrode and the thermocouple are attached to this stainless cover plate.

remove mounting bolts to remove infrared rotisserie burner

Under the ignitor cover is one of the rotisserie burner mounting bolts that has to be removed in order to replace the infrared rotisserie burner.

With the stainless cover plate removed we can see the incoming gas line but our first order of business is to free the infrared burner from the structure of the back wall of the grill.  Under the cover is a bolt on the right side of this infrared rotisserie burner which is holding the burner to the wall through the stainless frame around the ceramic section of the burner. Again this bolt is too soft with rust and corrosion so we have to grind and drill off the head instead of simply unscrewing the bolt.

Right side mounting bolt also has to be removed before pulling out the DCS infrared rotisserie back burner.

Once we have removed this right side mounting bolt — much easier to write the words than to remove the bolt with a grinder and drill and steel punch! — there is another bolt mounted in exactly the same way on the other side of the burner.  Again this bolt passes through the thin stainless steel section of a frame around the ceramic section of the infrared burner. Again the bolt must be ground down and broken free in order to free the rotisserie burner.

Rotisserie burner orifice elbow connection too damaged to remove

Gas line is attached with orifice elbow but the mounting nut is too damaged to be removed so the burner will slide free of the grill.

With the cover plate dislodged we have a square opening in the back wall where the aluminum gas line  attaches to the infrared rotisserie burner.  The aluminum gas line is not threaded or fitted with flare-nuts to tightly seal gas flow so we must use compression fittings to attach threading for the gas line.  This aluminum gas hose connects to the control valve all the way in the front control panel and again in and out of the safety-valve button before continuing all the way back where the gas line attaches to the rotisserie burner. To completely remove the burner we would usually unscrew a large one-inch nut on the inside of the burners venturi opening.  Like the mounting bolts, the elbow adaptors mounting nut is badly corroded and will not be unscrewed. The aluminum gas hose attaches to this elbow adaptor with a compression nut so the end of the elbow with the gas orifice can be held solid inside the rotisserie venturi where oxygen mixes with gas spraying through the orifice.  The elbow also has a fatter threading to match the opening in the end of the burner so the elbow can be bolted solid to the infrared rotisserie burner.  This is the anchor for the aluminum fuel line and the gas orifice. Obviously we have to remove the attachment in order to remove the rotisserie burner and we’ll need it in good shape to reinstall the next burner so we cannot simply cut it off.

Removing elbow from inside DCS grill

Removing elbow from inside DCS grill

Because the mounting nut is so badly corroded and will not allow us to simply unscrew the large nut and slide free the elbow with the gas line we will unscrew the compression nut from the top of the elbow. In order to remove the elbow by unscrewing the compression nut we can simply insert an open-end wrench to slowly move one flat at a time in this tight, small space until the nut slides free.  Even though the nut is disengaged the ferrel will be tightly pressed into the elbow where it seals the gas flow so we’ll need to lightly tap the gas line to pull the aluminum free.

pull rotisserie burner from back wall by pulling forward

Pull DCS infrared rotisserie back burner free from right side – opposite the gas connection – first and then slide away from the gas line to pull free of grill.

With the ignitor electrode cover gone and both mounting bolts removed and the orifice elbow adaptor disengaged we can now simply grab the burner and pull it free. Well… not exactly. We need to pull the burner out of the back wall from the side where there is Not A Gas Connection because the venturi section of the burner will have a section of wall in front of it where the mounting bolts attached. We will grab the burner to pull forward while sliding the infrared burner away from the gas hose connection. This is simple and exactly the same as removing any other barbecue grill burner.  Simply pull free from the far end and as the burner pulls away from the grill slide the entire burner away from the gas line so the structure slides free of the back wall.

Installing the elbow orifice in the infrared rotisserie burner venturi

Installing the elbow orifice in the infrared rotisserie burner venturi where gas flow mixes with oxygen so the fuel will actually burn as needed.

Before we attach the New Infrared Rotisserie Burner into the back wall of the grill we need to install the orifice-elbow-adaptor so the aluminum gas line can reconnect inside the grill.  Instead of using the same elbow with a thin hollow galvanized steel nut we will select the DCS orifice elbow with a solid brass nut.  This should not corrode so easily. The original orifice is drilled for the correct fuel type and regulated gas pressure so we will remove and install the orifice onto the new elbow.  The elbow installs without the mounting nut which is then threaded on tightly so the elbow is solidly attached to the infrared rotisserie burner.

Both rotisserie orifice elbow designs side by side

Both rotisserie orifice elbow designs side by side

This picture shows the DCS rotisserie elbow with the two different mounting nuts used by DCS through the years.  Truly, any elbow, any adaptor that will support the orifice can be used but it is usually best to use a DCS replacement because the gas line will be the same so the ferrel and compression nut match the threading on this adaptor.

Install the new DCS infrared rotisserie burner opposite of removing the old burner.

Install the new DCS infrared rotisserie burner opposite of removing the old burner by sliding the elbow orifice in and pressed forward until the body presses into the opening in the back wall.

Once the elbow is installed solid in the burner,  slide the burner into the back wall leading with the end with the orifice which needs to slide across to the square opening covered by the electrode cover.

Once the burner slides all the way over so the stainless frame is lined up with the Left Side  mounting bolt hole, the far right side can be pressed into the opening in the wall to line up the right side mounting bolt hole.       Because the burner frame is very tight around the ceramic tiles of ports on the burner it is common to need to use a knife blade or the end of a flat-head screwdriver to angle the tab out.   The frame tab can easily get caught on the opening so bend it slightly to slide over the edge and the holes will line up.  Once the right side is pressed into the wall the bolt holes will also line up easily.

Line up mounting holes to bolt the burner in the back wall of the grill

Line up mounting holes to bolt the burner in the back wall of the grill on the right side and the left side before attaching the aluminum gas connection to the orifice adaptor.

Although it is easier to leave the orifice adaptor in the grill when removing the infrared rotisserie burner, it is not uncommon to need to remove the elbow adaptor either.  Once the burner is mounted in place we need to line up the gas line and reattach the aluminum gas connection.  This is not easy because the gas line is stiff and compression adaptors are not designed to be removed and reattached. Line up the adaptor threading and the compression flare nut as straight as possible and tighten the connection as hard as possible.  In a compression seal, the brass collar around the aluminum gas hose is designed to be squeezed or compressed so its misshapen result seals any openings in the connection to make a fuel leak impossible. Using a compression ferrel that has already been connected can be unsafe so tighten this as hard as possible without damaging anything and make sure to leak check the connection before sealing the wall which makes the fittings difficult to access (pressurize the line by turning on the gas flow and pour soapy water over the connections while looking for bubbles denoting leaks; do not get any water on the actual infrared burner).

DCS infrared rotisserie burning

DCS infrared rotisserie burning

Once the infrared rotisserie burner is attached and the gas line is sealed to the burner we can ignite the infrared rotisserie burner and watch the ceramic tiles glow red.

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