LTR20091038, Rev.
WARNING If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Do not store an LP cylinder not connected for use in the vicinity of this or any other appliance. A fire resulting in serious injury or death may occur.
1 Safety Instructions Placement and Location • Cal Flame™ grills and carts are designed for outdoor use only. • Never locate this appliance in an enclosed room, under a sealed overhead structure, or in any type of enclosed area such as a garage, shed, or breezeway. Keep clear of trees and shrubs. • Do not place this grill under or near windows or vents that can be opened into your home. • Cal Flame™ grills are not intended for installation in or on recreational vehicles or boats.
Safety Instructions 2 • Never line the grill or side burners with aluminum foil. • When the unit is not in use, be sure to turn off the gas at the LP tank. • • • Only use dry pot holders and do not use a towel or other bulky cloth in place of pot holders. Moist or damp pot holders used on hot surfaces can cause burns. Do not install or operate your grill unit in such a manner that the cross ventilation openings are blocked.
3 Installation / Assembly We recommend the installation, adjustment and service of your new grill be performed by L.M.S. qualified installers and service technicians to ensure proper operation and prevent accidents. When planning your Cal Flame grill or cart location, access to gas lines and 110V power supplies should be considered. The location with the shortest gas line run is recommended. A grounded, dedicated, 15A, 110V, GFCI power source is required for use of your appliances (e.g.
Installation / Assembly 4 Model Number BBQ08874F BBQ04103034 Description 4 Burner Flat Drop In Grill Drip tray cut-out A 21 ¾” Width 37 ¾” B 1 ¾” Depth 22 ¾” C 5” Cut-out for flat drop-in grill and drip Height tray 8 ¾” D 6 ½” DEPTH WIDTH GRILL CUT-OUT D C B A DRIP TRAY CUT-OUT Model Number BBQ07868P BBQ07862P BBQ07889P BBQ07891P BBQ08967P Description 2 Drawer Storage Griddle and Griddle Storage 30” Warming Drawer Cutting Board and Drawer 110V Electric Pizza Oven Width 10 ¾” 13 ½” 28 ¾” 13
5 IMPORTANT: Cal Flame™ grills are manufactured to operate on either liquid propane (LP) or natural gas (NG) and cannot be converted. To verify the grill’s operating fuel, check the serial number label in the back of the chassis as you are looking at the grill from the front. Either LP or NG will be marked on the operating tab, indicating the proper operating fuel. Attempting to convert Cal Flame™ grills from one fuel to another may result in serious injury and will void the warranty coverage.
Installation / Assembly 6 LP Gas Tank Requirements For plumbed-in LP installation, use a convertible regulator and set it for LP gas. Maximum line pressure for plumbed-in propane is 14” WC (3.5 kPa). Minimum line pressure for propane is 11” WC. The grill unit must be used with the gas pressure regulator. The regulator will control and maintain a uniform gas pressure in the manifold. The burner orifices have been sized for the gas pressure delivered by the regulator.
7 Requirements Always check the rating plate to make sure the gas supply you are hooking up to is the gas type the grill is manufactured for. IMPORTANT: Never connect the grill to an unregulated gas supply. The installation of this appliance must conform with local codes or, in the absence of local codes, to the national fuel gas code, ANSI Z223.1a-1998. Installation in Canada must be in accordance with the standard CAN/CGA-B149.2, Propane Installation Code.
Installation / Assembly 8 Installing the Transformer All grills with electrical components such as lights or a convection fan will require the transformer to be installed and plugged in before you can use it. This needs to be done before the grill is inserted in the island or modular cart. When the transformer is attached to the grill chassis, use care in placing the grill in the island cutout to avoid hitting the transformer. 1. Remove the transformer and the metal screws from the plastic bag. 2.
9 You will need a second person to help you to avoid damaging the grill, the transformer, or your barbecue island. Before installing a grill or side burner in any island or cut out, make sure that the opening is not bigger than the outside frame of the grill unit. The grill should rest on the lip of the frame. For drop-in accessories, adequate cross ventilation must be designed into enclosure to ensure the drop-in grill or side burner does not become overheated.
Installation / Assembly 10 Installing Side Burners 3. Connect the flexible hose (male end) to the pipe tee. 1. Assemble a 3/8” pipe nipple to the 3/8” pipe tee using Teflon tape or pipe sealant. Use only sealant that is approved for use on LP gas. 4. Install and secure the side burner into the island by simply setting it in place. 2. Install the pipe tee assembly to the grill intake pipe. Tighten assembly and align the branch opening of the tee with the hole of the cabinet. 5.
11 Using Your Grill We recommend you wash your entire grill with soap and water prior to lighting it for the first time. Oils are used during the manufacturing process and some residual oil may still be on the stainless steel parts of your grill. Washing will reduce the possibility of discoloration. We also recommend you keep your grill covered when not in use. This will minimize the amount of dust and dirt that accumulates on your grill and extend the life of your grill.
Using Your Grill 12 Lighting the Grill Each time you light the grill, check the following: • • Inspect the hose before using the grill. If there is excessive abrasion or wear, or if the hose is cut, it must be replaced prior to using the grill. If you need a replacement hose, contact your Cal Flame dealer. Ensure the area around the barbecue is clear of flammable substances such as gasoline, yard debris, wood, etc.
13 Before lighting, make sure all burner controls are off. Do not attempt to light the burners if the smell of gas is present. Check the connection with a soap and water solution after attaching the hose. For LP units, make sure there is gas in the tank and it is sitting upright. For natural gas units, make sure the shut off valve is on. 3. Turn the control knob to HIGH and preheat the grill for 15 minutes. Close the top cover during the appliance preheat period. 1. Make sure the drip tray is in place.
Using Your Grill 14 Cooking with a Convection Grill A convection grill has an internal fan that circulates heated air evenly throughout the grilling area when the hood is closed. Cooking in this way distributes heat more efficiently so you no longer have to be concerned with “hot spots” on the grill where food tends to burn. The fan switch is located at the far left of the front panel of the grill. EXHAUST VENTS HEAT THAT IS DRAWN IN FROM THE BACK.
15 Using Your Grill Turning on and off the Lights and Fan The ON / OFF switch controlling your halogen light is located at the control panel on the front lower left side. Certain models of the Cal Flame grill are equipped with either one or two halogen light. Your grill is equipped with a grounded (3 prong) 120 VAC plug located in the lower left rear corner of your cart and must be plugged into a permanent grounded 120 VAC outlet with a dedicated 15amp GFI breaker.
Cleaning and Maintenance 16 Cleaning and Maintenance To ensure safe and proper maintenance, we recommend you follow these directions carefully. Clean internal parts of the grill regularly as determined by the amount of use and foods cooked. The entire grill should be cleaned at least once a year. In addition, keep the area around your grill or cart clear and free from combustible materials, gasoline, and other flammable vapors and liquids. Do not obstruct the flow of combustion and ventilation air.
17 Charcoal Grill Be sure to unplug the electrical supply before cleaning any part of your Cal Flame barbecue. Spray cabinet area with a soap and water solution. Rinse with a gentle stream of fresh water. To prevent burns or injury, make sure the grill is completely cool before cleaning. After initial usage, areas of the grill may discolor from the grill’s heat. Griddle To prevent burns or injury, make sure the griddle is completely cool before cleaning.
Cleaning and Maintenance 18 Light Bulb Replacement WARNING: Never attempt to replace a light bulb when the grill is in use. Serious burns will result. WARNING: Never touch halogen bulbs with your bare fingers. Use a tissue or a small piece of paper to handle bulbs. Oils from your hands will damage halogen bulbs. Light Removal 1. Open the grill hood and locate the glass light covers at the back of the grill. 2. Using a small screwdriver, gently pry the light cover away from the housing.
19 Problem: Smell of gas is present Solution: Check for loose connections in the gas line. Perform a leak test following the procedure described in this manual. Problem: Burner does not ignite Solution: Use the following procedure with the figure below. Check the position of the sparker tip. It should be pointing forward towards the front of the burner. • • • • • Make sure there is a blue spark at the electrode tip to the burner.
Appendix 20 Problem: Yellow Flame Solution: Once the entire burner is operating, check the flame color to be sure that it is mostly blue. Some yellow at the tips may be present due to impurities in the fuel. If the flame is golden or yellow in color, the reason could be seasoning salts, oil film, or other foreign matter on the burner. Problem: Plugged orifice Solution: Unplug the orifice as follows: • Remove cooking grills, flame tamer and grease tray.
21 WARNING! You must have an authorized service technician perform this procedure. If these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. Lloyd’s Material Supply (L.M.S.) will not be held responsible for an improperly converted gas grill. All Cal Heat grills are manufactured as standard liquid propane (LP) grills and can be converted to burn natural gas (NG). There are two steps required to convert a grill from LP to NG.
Appendix 22 Step 2: Changing the burner orifices 1. Replace the infrared burner orifices a. Using a 13mm wrench, remove the orifice for the infrared burner. b. Apply pipe compound to the fitting threads where you will place the new orifice. c. Screw on the correct orifice for your grill until it is finger tight. d. Tighten the orifice with the 13mm wrench. e. If you have dual infrared burners, repeat the previous steps for the second burner. f. You will need: • • • • Replace the back cover. 2.
23 Appendix Installing and Replacing Infrared Burners 1. Disconnect or shut off the liquid propane or natural gas line connect to the grill. Wait until the burners cool down. 2. Open the hood and remove the grate and flame tamer on top of the burner you want to replace. 3. Through the access door underneath the grill, find the round stud and locking pin that locks the burner you want to replace. 6. Take the burner out of the grill and store it in a safe and dry place. 7. Install the infrared burner.
Appendix 24 2009 Warranty LMS offers the following limited warrants against defects in material and workmanship on Cal Flame barbecue products and components: Lifetime Component Warranty Lifetime Equipment Warranty LMS warrants against deterioration and corrosion LMS warrants against deterioration and corrosion • • • • • • • • • Flame Tamers -- Stainless Steel Burners - Cast Stainless Steel Grates - Stainless Steel Griddle Rotisserie - HD Stainless Steel Mountings - Stainless Steel Grill Lid and Bo
25 LMS shall not be liable for loss of use of the barbecue grills, carts, related hardware or other incidental or consequential costs, expense or damages, which may include, but are not limited to, removal of permanent deck or other custom fixtures or the necessity for crane removal. Any implied warranty shall have duration equal of the applicable warranty stated above.
Locating the product serial number The serial number of your Cal Flame grill is located on the back and is visible when the hood is down. You will need this number to properly register your grill or cart and activate coverage. Write this information in the space provided below.
