LTR50001038, Rev.
Safety Instructions Placement and Location . . . . . . . . . . . . . . . . Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Repair . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions Regarding Children . . . . . . . . .
1 Safety Instructions 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. • 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 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. Use handles or knobs. • Never line the grill or side burners with aluminum foil.
3 Built-in Construction LMS Inc. will not be held responsible for property damage, injury, or death as a result of locating a grill enclosure in a non-approved location or using non-approved construction materials. We strongly recommend that grill owners hire a contractor to construct the built-in enclosure.
Built-in Construction 4 DEPTH WIDTH 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 DEPTH acceptable, provided it is non-locking and can be opened without the use of tools.
DEPTH 5 HEIGHT Built-in Construction Built-in Dimensions cont. Minimum Clearance WIDTH WIDTH The dimensions shown below are for Cal Flame appliances only.
Built-in Construction T 6 Screen Vents Enclosure Ventilation For proper ventilation, the base structure must be constructed using one of two designs: Minimum 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.
the back of the grill. (Use gas rated tape seal on all connections). Connect the last open line to the side burner C (Use gas rated tape seal on all connections) NOTE: You will need to use a gas rated sealer on gas connectors that are not flared. 7 Built-in Construction Plumbing for Side Burners 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. 2. Install the pipe tee assembly to the GAS LINE grill intake pipe.
Installation 8 Installation 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. 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.
Gas Connection 10 Gas Connection 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. Consult your Cal Flame dealer for information on converting your gas grill. Owners must not convert their grills themselves. Attempting to convert the grill from LP to NG may result in serious injury and will void the warranty coverage.
11 Gas Connection 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.
Gas Connection 12 Natural Gas 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. Connection 1.
13 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 14 Grill Controls The controls shown below are for Cal Flame drop-in grills. Familiarize yourself with these controls before lighting your grill. The ON / OFF switch controlling the fan and halogen light is located on the control panel at the front lower left side. Barbecue Grills www.calflamebbq.com LTR50001038, Rev.
15 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. before each use. • Ensure the propane cylinder, regulator, and rubber hose are installed in a location not subject to heating above 125º F (51º C).
Using Your Grill 16 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. Convection Fan A convection grill has an internal fan that circulates heated air evenly throughout the grilling area when the hood is closed.
17 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 9 for instructions.
Optional Grill Accessories 18 Optional Grill Accessories These grill accessories are optional and may be ordered directly from Cal Flame customer service. See page 21 for ordering information. 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.
19 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. Set the charcoal tray in the grilling area so that the notches in the side rest on the round metal posts attached to the inside of the grill area.
Optional Grill Accessories 20 Deep Fryer Helper Set The Deep Fryer Helper can turn part of your grill into a deep frying station. It is designed to fit in any Cal Flame grill. The Deep Fryer Helper Set is shipped with its own instructions for placement and use. Read them carefully before use. The Deep Fryer Helper Set comes with two commercialsized fryer baskets, a built-in thermometer, and storage hangers allow baskets to be stored within unit.
21 Cleaning and Maintenance 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 22 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. Do not use Instant Rust Out, WD-40, or Sheila Shine near food or on food preparation surfaces as it is a health hazard.
23 Steam Cleaning Your Grill 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. If you spray the burners, ignite them and let them burn for about 10 minutes to prevent any water from accumulating inside them. Inspect each burner for damage (cracks and holes). If any damage is found, discontinue grill usage until you replace the burner.
Cleaning and Maintenance 24 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.
25 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 26 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.
27 Appendix 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 28 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.
29 Converting from LP to NG All Cal Flame 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. You must perform both steps. Step 1: Switching the regulator behind the grill Step 2: Changing the burner orifices The conversion kit provided with your grill may include some or all of the parts shown at right, depending on the size and model of your grill.
30 Gas Conversion (continued) Appendix Step 2: Changing the burner orifices You will need: • • 1. Replace the main burner orifices 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.
Gas Conversion (continued) 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 • You will need: • • 7mm wrench, socket, or nut driver One or two 1.75mm orifices (depending on your side burner) Pipe compound suitable for natural gas • a.
Appendix 32 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.
33 - 2 1 + ROTISSERIE PLUG 1 ROTISSERIE PLUG 2 1 WHITE 2 WHITE WHITE LIGHT AND CONVECTION FAN SWITCH WHITE BLACK TRANSFORMER PLUG Appendix Wiring Diagram RED WIRE NUT WIRE NUT HALOGEN LIGHT HALOGEN LIGHT CONVECTION FAN Barbecue Grills LTR50001038, Rev. C www.calflamebbq.
14 23 28 29 4 10 32 www.calflamebbq.com 26 31 2 17 19 19 5 34 16 17 18 25 20 8 3 33 30 7 11 1 12 24 19 9 13 BACK BURNER ORIFICE NG: BBQ04101072 LP: BBQ04101073 MAIN ORIFICE NG: BBQ04101059 LP: BBQ04101067 15 See following page for part numbers and ordering information. 27 22 6 Appendix 34 Replacement Parts Barbecue Grills LTR50001038, Rev.
35 Item No.
Appendix 36 Limited Warranty All Cal Flame models are manufactured with the highest quality appliances and are warranted to be free from defects in material and workmanship at time of delivery. LMS warrants barbecue grills and associated hardware from deterioration, corrosion, and defects in material and workmanship for a period of one year from the original date of delivery, with the exception of plastic items and glass light covers, which are warranted for 90 days.
37 Appendix Disclaimers LMS shall not be liable for loss of use of the barbecue grills, 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. Legal Remedies This limited warranty gives you specific legal rights.
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.
