LTR50001137, 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.
Safety Instructions 1 the grill and is visible when the hood is lowered or on the right side of the chassis. There is an area on the back cover of this manual where you can write down this information. Placement and Location • Cal Flame™ grills 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.
Safety Instructions 2 motor cord away from the heated areas of the grill. hanging garments while using your grill. Fabric may ignite and result in personal injury. • Never use the grill or side burner in windy conditions. If used in a consistently windy area a windbreak will be required. Always adhere to the specified clearances listed in this manual. • When using the grill, do not touch the grill rack, burner grate, or immediate surroundings as these areas become extremely hot and can cause burns.
Proper Location of the Grill When planning your Cal Flame grill location, access to gas lines and 110V power supplies should be considered. If you are using natural gas, the location with the shortest gas line run is recommended. You may need a grounded, dedicated, 15A 110V GFCI power source for use of your appliances (e.g., lights, rotisserie, refrigerator, receptacles, etc.).
Built-in Construction 4 Built-in Construction Note: The terms “built-in construction” and “grill enclosure” as used in these instructions refer to any method for installing a barbecue island for use. A barbecue island is both built-in constructions and a grill enclosure. Read these instruction before constructing your grill enclosure. The Cal Flame convection grill is expected to be used with a Cal Flame barbecue island.
5 DEPTH Built-in Dimensions Minimum Clearance DEPTH Plan the installation so that the electrical connection, gas shut-off valve, and pressure regulator are accessible inside the base enclosure. The gas valve shall be readily accessible for hand operation. A door on the enclosure to gain access to the gas valve is acceptable, provided it is non-locking and can be DEPTH opened without the use of tools.
Built-in Construction ner DEPTH 6 HEIGHT Built-in Dimensions cont.TH Minimum Clearance WIDTH WID The dimensions shown below are for Cal Flame appliances only.
Screen Vents 7 Built-in Construction Enclosure Ventilation ForMinimum proper ventilation, the base structure must be constructed using one of two designs: Clearance 1 An enclosure with one side open Screen Vents 2 An enclosure having four sides, a top, and bottom At least two ventilation openings at cylinder valve level shall be provided in the side wall, equally sized, spaced at 180 degrees and unobstructed.
Gas and Electrical Supply Requirements 8 Gas and Electrical Supply Requirements Gas Requirements Gas Requirements and Connection IMPORTANT: The Cal Flame grill is manufactured to operate on liquid propane (LP). However, it can be converted to operate on natural gas (NG) by an authorized service technician. This barbecue grill does not include the parts for converting to NG. The gas conversion kit can be ordered separately. The part number for the conversion kit is BBQ07101045.
9 NG Service Installation and Connection Natural gas 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. You do not need to hire a contractor to install your natural gas service, but you need to make sure you have all required permits and ensure the installation complies with State and local code.
Installation and Connection 10 Installation and Connection Connecting the Grill and Side Burner These instructions show you how to connect a grill only or a grill and side burner combination. If you plan to convert to your grill from LP to NG, you need to do this before it is connected to a gas source. Grill conversion instructions can be found on page 31 and ordering information can be found in this manual on page 37. There are a few differences between connecting to LP and NG. 1.
11 Connect the Gas Line to the Grill Note: Make sure you have converted the grill for natural gas before connecting the gas line to the regulator. See page 31 for instructions on converting the grill from LP to NG. Connecting the grill only If you have a grill and side burner combination, go to step 3.b. Slide the grill forward about six inches and connect the gas line to the grill using the appropriate connection for your gas type.
Connect the Gas Line to the Grill and Side Burner One or two 1/2” to 3/8” flare reducers • Two 3/8” flex lines • LP gas line with regulator OR 3/8” NG flex line Connect two 3/8” flex lines to the ends of the T connector that will connect with the grill and side burner. Connect either a third flex line (if you are using NG) or a LP gas line (if you are using LP) to the third end of the T connector as shown at left. b.
13 Installation and Connection 4. Connect to a Gas Source Liquid Propane Connection Use the pressure regulator and hose assembly supplied with the grill, or a regulator and hose assembly with the same specifications. Replacement LP regulator and hose must have a coupling nut that will connect to a QCC-1 cylinder valve on one end and a female fitting that will connect to a 3/8” tapered fitting on the grill manifold. See the figures below. Connect the brass fitting to the manifold behind the grill.
Installation and Connection 14 Attaching the Rotisserie Motor Attach the two brackets to the sides of the grill, one on each side, using two screws as shown below. Slide the rotis motor on one of the brackets as shown below. The rotis motor will work on either side of the grill. P4, P5, and P6 Barbecue Grills www.calflamebbq.com LTR50001137, Rev.
Using Your Grill 15 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 16 Warning NEVER cover the entire cooking or grill surface with griddles or pans. Overheating will occur and burners will not perform properly when combustion heat is trapped below the cooking surface. CAUTION: NEVER spray water on a hot gas unit. This may damage porcelain or cast iron components. Grill Controls The controls shown below are for the P4, P5, and P6 drop-in grills. Familiarize yourself with these controls before lighting your grill.
17 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. • Ensure there is no blockage of the airflow through the vent space located below the face of the unit.
Using Your Grill 18 Proper Burner Flame Flame Color and Height The burner flame has been set in the factory and should already be adjusted for proper height and intensity. Periodically, you may wish to check each burner’s flame for color, height, and intensity. Remove the grill rack and the flame tamer over the burner you want to inspect. When the burner is operating properly, the flame will appear between light to dark blue, with occasional yellow bursts (due to impurities in propane -- this is normal).
19 Using Your Grill Heat Distribution on the Cooking Grates When you place food your Cal Flame grill, remember that the back of the grill tends to be hotter than the front. As your food cooks, you should periodically shift it to different spots on the cooking grates to ensure everything cooks evenly without burning. Drop-in Griddle Remove any two cooking grates for the griddle space and set the griddle in the empty space.
Using Your Grill 20 Cooking with the Rotisserie The rotisserie cooks with the infrared back burner, which provides intense searing radiant heat. The location of the rotisserie and burner allows the placement of a rotisserie-basting pan (NOT included) beneath the food to collect juices and drippings for basting and gravy. Before you can use the rotisserie, you need to mount the brackets and motor to the grill. See page 14 for instructions.
Optional Grill Accessories 21 • Contact an authorized selling dealer • Call LMS Customer Service at (800) 225-7727 • Visit us at www.quickbbqparts.com Sear Zone Infrared Burner The Sear Zone infrared burner can be use in place of any regular burner. Producing intense infrared heat, it cooks quickly with searing heat to seal in juices. (Note: The Sear Zone infrared burner is NOT the same as the infrared back burner used with the rotisserie.
Optional Grill Accessories 22 Charcoal Tray Use Turn part of your Cal Flame grill into a charcoal and gas grill. Turn off the gas and wait for the grill to cool before setting the Charcoal Tray in place. Placement 1. Remove two grates (left or right side) and the flame tamers (the angular metal pieces covering the burners). Do not remove the burners. BBQ11859 2.
Cleaning and Maintenance 23 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 clear and free from combustible materials, gasoline, and other flammable vapors and liquids. Do not obstruct the flow of combustion and ventilation air. DISCONNECT ELECTRICAL SUPPLY BEFORE CLEANING ANY PART OF THE GRILL.
Cleaning and Maintenance 24 grain until excess liquid is removed and the surface shines. It should not be oily to the touch, however some residue is acceptable. Furniture polish, such as Old English, can be effective for polishing stainless steel and protecting the surface. 2. Rust removal with WD-40 or Sheila Shine: Spray exterior stainless steel surfaces with WD-40 or Sheila Shine and wipe down with a dry cloth or paper towel until surface is free of rust.
25 Use a wire brush to clean the outer surface of each burner to remove food residue and dirt. Clean any clogged ports with a stiff wire such as an opened paper clip. Inspect each burner for damage (cracks and holes). If any damage is found, discontinue grill usage until you replace the burner. Upon reinstallation, inspect the gas valve orifices for cleanliness and condition and the location of the igniters. When you replace the burners, you do not need to replace the locking pins.
Cleaning and Maintenance 26 Seasonal Cleaning If you haven’t used your grill in a few months, we recommend that you clean the burners and the interior of your grill. Cleaning the burners periodically will keep them burning evenly and cleanly and help prevent “flashback”, a type of fire in and around the gas tubes. This happens when spiders and small insects inhabit or make nests in the burner tubes, obstructing the gas flow.
27 While the burners are out of the grill, you can use this opportunity to clean the interior of your grill thoroughly. You should still have the drip pan in place to catch water and grime as you clean the grill interior. When the grill interior is clean, remove the drip pan. Dump out any water and grime residue and spray it off with a garden hose. Dry both the grill interior and the drip pan thoroughly to prevent water damage. 5.
Cleaning and Maintenance 28 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. Cal Flame grills use two different types of light housings. These instructions describe how to change the bulb in both types. Light Lens with Screw Clip 1.
Appendix 29 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: Note: Turn off the gas at the source while troubleshooting. 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 30 Problem: Plugged orifice Solution: Unplug the orifice as follows: • Remove cooking grills, flame tamer and grease tray. • Remove burners from the bottom of the firebox by pulling the locking pin from beneath the burner peg using a standard screwdriver or needle nose pliers. • Carefully lift each burner up and away from the gas orifice. • Remove the orifice from the control valve. • Gently clear any obstruction with a fine wire.
31 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 (LMS) will not be held responsible for an improperly converted gas grill. All Cal Flame grills are manufactured as standard liquid propane (LP) grills and can be converted to burn natural gas (NG).
Appendix 32 Step 2: Changing the burner orifices 1. Replace the main burner orifices You will need: a. Remove the grates, flame tamers, and drip tray from the grill. See figure below. • • • 6mm socket or nut driver Two to five 1.9mm orifices (depending on your grill Pipe compound suitable for natural gas WIDTH Orifice HEIGHT WIDTH WIDTH b. Remove the locking pins from the end of the burners. The locking pins are accessible by removing the drip tray and tilting the grill back.
33 3. Replace the side burner orifices You will need: • • • Either a 13mm or 10mm open end wrench One #50 orifice (for single infrared burner) OR Two #54 orifices (for dual infrared burners) OR One #52 orifice (for single infrared burner) • Pipe compound suitable for natural gas • a. Unscrew the back cover from the grill and lift it up and under the grill hood. b. Using a wrench, remove the orifice for the infrared burner. c.
Appendix 34 Installing Sear Zone Burners 1. Disconnect or shut off the LP or natural gas line connected to the grill. Wait until the burners cool down. 2. Open the hood and remove the grate and flame tamer on top of the stainless steel 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. 4. Carefully remove the locking pin with your fingers. 5.
35 Appendix Wiring Diagram PUSH BUTTON LIGHT RED TRANSFORMER PLUG - 2 1 RED + GREEN - + NC NO C WHITE GREEN RED QUICK CONNECTOR WHITE WHITE GREEN WHITE WHITE WHITE QUICK CONNECTOR HALOGEN LIGHT HALOGEN LIGHT NOTE: USE TERMINAL CONNECTORS TO ALL WIRE ENDS THAT CONNECT TO ALL ELECTRICAL COMPONENTS. NO SOLDERING. P4, P5, and P6 Barbecue Grills LTR50001137, Rev. K www.calflamebbq.
Appendix 36 P6 Dimensions P4, P5, and P6 Barbecue Grills www.calflamebbq.com LTR50001137, Rev.
37 Appendix See following page for part numbers. To order replacement parts: • contact dealer. authorized selling • Call LMS Customer Service at (800) 225-7727. • Visit us at www.quickbbqparts.com. 2 25 33 8 7 34 24 17 27 26 19 29 6 28 14 16 13 11 15 10 23 21 3 31 30 12 5 1 5 18 22 20 9 an 4 Replacement Parts P4, P5, and P6 Barbecue Grills LTR50001137, Rev. K www.calflamebbq.
Appendix 38 Item No.
39 25 Part Manifold Grill Size Part # 4 burner BBQ08000514 5 burner BBQ08000515 6 burner BBQ18P06-MANIF 26 Upper rack holder, left side All BBQ04100706 27 Stainless steel burner All BBQ07100661 Back burner valve (LP) All BBQ04101014 Back burner valve (NG) All BBQ04101013 Main burner valve (LP) All BBQ04101016 Main burner valve (NG) All BBQ04101015 30 Back burner deflector All BBQ08300441 31 Button light switch, PV3F2G0SS All BBQ04300425 32 120V rotisserie motor 33 S
Limited Warranty This Limited Warranty is extended to the original purchaser of a Cal Flame P4, P5, or P6 grill manufactured after January 1, 2018 and installed for residential use in the United States and Canada.
41 Warranty Limitations This Limited Warranty is void if Cal Flame or its designated representative determines that the grill has been subjected to alteration, neglect, misuse or abuse, or freight damage caused by the common carrier; any repairs or fuel conversion have been attempted by anyone other than a designated representative; or if the failure is caused by accident, acts of God or other causes beyond the control of the Manufacturer.
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 and activate coverage. Write this information in the space provided below.
