LTR50001050, 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. Safety Instructions Placement and Location . . . . . . . . . . . . . . . . Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Repair . . . . . . . . . . . . . . . Storage .
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. • We recommend that a licensed contractor install your Cal Flame™ grill. Installation must conform to local codes, or in the absence of local codes, with either the National Fuel Gas Code, ANSI Z223.
Safety Instructions 2 • When handling LP gas line and connectors, do not allow them to come in contact with any metal surfaces of the cabinet. Do not drop LP connectors. • Do not use fuel such as charcoal briquettes in gas grills. • Gas sources to the grill and side burners must be regulated. Do not operate grill or side burners if regulators have been removed, fire or explosion can occur. • Never leave the grill and side burners unattended when in use.
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.
WIDTH Minimum Clearance DEPTH HEIGHT WIDTH WIDTH DEPTH Plan the installation so that the electrical connection, gas shut-off valve, and pressure regulator are WIDTH 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 opened without the use of tools.
HEIGHT Minimum Clearance 6 Built-in Construction ner DEPTH WIDTH WIDTH The dimensions shown below are for Cal Flame appliances only.
7 Built-in Construction Enclosure Ventilation For proper ventilation, the base structure must be constructed using one of two designs: 1 An enclosure with one side open 2 An enclosure having four sides, a top, and bottom The second type of enclosure must be constructed with the following specifications: • 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 Gas and Electrical Supply Requirements Natural Gas 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.
Gas and Electrical Supply Requirements 10 Electrical Supply Requirements You will need a dedicated 120V 10 amp grounded electrical service. The power supplied to your grill enclosure must be on a dedicated circuit with no other appliances or lights sharing the power. You do not need to hire a contractor to install your electrical service, but you must ensure you have all required permits and the installation complies with State and local code.
Installation and Connection 11 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 29 and ordering information can be found in this manual on page 32. There are a few differences between connecting to LP and NG. 1.
Installation and Connection 12 2. 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 29 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 2.2. Slide the grill forward about six inches and connect the gas line to the grill using the appropriate connection for your gas type.
13 Connect the Gas Line to the Grill and Side Burner 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. Connect to the grill The gas manifold for the convection grill can be configured for both LP and NG.
Installation and Connection 14 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.
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 Grill Controls The controls shown below are for the G4 grill. Familiarize yourself with these controls before using your Cal Flame™ barbecue. Off High Low Burners 1 2 3 4 Grill Knob Opera on Lighting the Burners 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. See page 8 for LP connection instructions and specifications.
17 WARNING: Do not use standard matches or cigarette lighters to perform match lighting procedures. Serious burns can occur and lighters can explode. 1. Open the hood. 2. If you have just attempted to light the burner, allow five minutes for any accumulated gas to dissipate. 3. Slide out the drip tray from the grill. 4. Keep your face as far away from the burners as possible. 5. Light and insert a long stem match, holding it near the burner ports. 6.
Using Your Grill 18 Flame Adjustment You can adjust the flame height to be higher or lower according to your preferences. This may be necessary if the flame goes out on the low flame setting. 1. Light the burner and adjust the flame as low as it can go without going out. 2. Remove the knob and insert a long flat standard screwdriver into the hole at the lower right side of the valve. 3. Turn the flame adjustment screw to adjust the flame to your preference.
Optional Grill Accessories 19 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.) Instructions for installing the optional Sear Zone burner are on page 34. BBQ07890P Pizza Brick Tray You can use your grill as a pizza oven using the pizza brick tray.
Using Your Grill 20 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 BBQ11859 1. Remove two grates (left or right side) and the flame tamers (the angular metal pieces covering the burners). Do not remove the burners. 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.
21 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. The lid closes and seals for easy storage–wet (with oil) or dry (drained).
Cleaning and Maintenance 22 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 clear and free from combustible materials, gasoline, and other flammable vapors and liquids. Do not obstruct the flow of combustion and ventilation air.
23 methods of rust removal we 1. Rust removal with Instant Rust Out: Spray exterior stainless steel surfaces with Instant Rust Out. Let it stand for about 30 seconds, then wipe with a clean cloth. Apply a second time if necessary. Instant Rust Out will leave a white residue which can be rinsed off with water. Wipe the grill dry with a clean cloth and apply Sheila Shine or WD-40 as a surface protectant. 2.
Cleaning and Maintenance 24 IMPORTANT: Prior to starting this procedure, turn OFF all of the gas control knobs, shut off the fuel supply, and disconnect the fuel line. The burners can be removed by removing the locking pins and lifting them out. The locking pins are located under the grill toward the back. They are used to keep the burners in place during shipping and are not necessary to operate your grill.
25 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.
Cleaning and Maintenance 26 4. Clean the grill interior 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.
Appendix 27 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 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 30 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 H IDTyour Two to five 1.9mm orifices (dependingWon grill Pipe compound suitable for natural gas HEIGHT Orifice 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.
31 a. Remove the grate, burner cap and burner diffuser from the side burner. You will need: b. Using a 7mm wrench, remove the orifice for the burner. • • c. • Apply a small amount of pipe compound to the orifice threads. 7mm wrench, socket, or nut driver One or two 1.75mm orifices (depending on your side burner) Pipe compound suitable for natural gas d. Screw in the orifice until it is finger tight. e. Tighten the orifice with the 7mm wrench. f.
Appendix 32 Replacement Parts See following page for part numbers. To order replacement parts: • contact an authorized selling dealer. • Call LMS Customer Service at (800) 225-7727. • Visit us at www.quickbbqparts.com. TION 051-CC 14 589-CC 688-CC 21 2 20 9 10350 5 03000 00972 10351 4 01028 18 00659 00641 12 00512 01043 15 00658 19 16 04055 13 10 1 00662 010-CC 6 01016 7 01257 20171 8 00707 00706 3 040 015 17 11 G Series Gas Grills www.calflamebbq.
33 Item No.
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 This Limited Warranty is extended to the original purchaser of a Cal Flame G Series grill manufactured after January 1, 2014 and installed for residential use in the United States and Canada. R E D WA R R A N TY YEAR UCTUR LI MIT 10 Year Structure Cal Flame grill structure or frame housing is warranted against rust-through, due to defects in material or workmanship in normal household use for ten years from the original date of purchase.
Appendix 36 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. Neglect, misuse and abuse include any installation, operation or maintenance of the grill other than in accordance with the instructions contained in the owner’s manual provided with the grill. Corrosion, scratching and discoloration due to improper use and care of this outdoor product, is excluded from this warranty.
37 Appendix G Series Gas Grills LTR50001050, Rev. E www.calflamebbq.
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.
