Calflame G3 User manual

reserved. Duplication without written

consent is strictly prohibited.

Cal Flame ® is a registered trademark.

Due to continuous improvement programs,

all models, operation, and/or specications

are subject to change without prior notice.

LTR20091050, Rev. A

12/11/08

CONTACT INFORMATION

For customer service, please contact

your authorized dealer immediately. If

you need additional information and/or

assistance, please contact:

Customer Service Department

1462 East Ninth Street

Pomona, CA 91766

Toll Free: 1-800-CAL-SPAS

Fax: 1-909-629-3890

www.calspas.com

Installation / Assembly

Cabinet Cut-out Dimensions.............5

LP Gas ..............................6

Natural Gas ..........................8

Leak Testing Procedure.................9

Installing the Grill in a Barbecue Island ..10

Using Your Grill

Grill Controls ........................11

Basic Grill Operation ..................12

Electronically Lighting the Grill .........13

Manually Lighting the Grill .............14

Cleaning and Maintenance

Stainless Steel .......................15

Drip Pan ............................16

Covering Your Grill ...................16

After Use Care .......................16

Appendix

Troubleshooting .....................17

Replacement Covers ..................20

Removing and Replacing Burners .......20

2009 Warranty.......................21

Save these instructions!

Safety Instructions

2009 G3, G4, G5 Grills

LTR20091050, Rev. A

www. c a l s p a s . c o m

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.

Maintain sufcient distance as to not overheat any overhead • combustible material such as a patio cover.

The area surrounding your new grill should be kept clean and free•

from ammable liquids and other combustible materials such as

mops, rags or brooms, as well as solvents, cleaning uids, and

gasoline.

Do not use the grill or area surrounding the grill as a storage area•

for ammable or plastic items. Do not store the liquid propane

(LP) cylinder in the vicinity of this or any other appliance when it

is not being used.

Set-Up

Before installing built in grills in enclosures, copy all pro• duct

information such as model number, serial number and gas type

(LP) and store information in a safe place. This information is

located on a plate located behind 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.

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

Z223.1 / NFPA54, Natural Gas and Propane Installation Code,

CSA B149.1, or Propane Storage and Handling Code, B149.2),

as applicable.

To prevent re and smoke damage, remove all packaging material • before operating grill.

Safety Instructions

WARNING: Improper installation, adjustment, alteration,

service or maintenance can cause injury or property damage. Read

the installation, operating and maintenance instructions thoroughly

before installing or servicing this equipment.

Safety Instructions

2009 G3, G4, G5 Grills

LTR20091050, Rev. A

www. c a l s p a s . c o m

Before you start cooking, clean the entire grill thoroughly with hot,• soapy water. This is necessary to remove residual solvents, oil and

grease used in the manufacturing process. The grates should also

be thoroughly cleaned in the same manner.

Operation

Do not use grill for oth• er than intended use.

In the event that a burner goes out, turn burner knobs to the full• OFF position, fully open the grill hood and let it air out. Do not

attempt to use the grill until the gas has had time to dissipate.

Never use the grill if the drip pan is not properly installed. Drip• pan should be pushed all the way to the rack located just under

the grill. Fire or explosion can result from an improperly installed

drip pan.

Keep all electrical supply cords away from the heated areas of the• grill.

Never use the grill in windy conditions. If used in a consistently•

windy area a windbreak will be required. Always adhere to the

specied clearances listed in this manual.

Never line the grill with aluminum foil.•

When the unit is not in use, be sure to turn off the gas at the LP• tank.

Do not install or operate your grill unit in such a manner that the• cross ventilation openings are blocked. Fresh air must be able

to pass though installed vents to safeguard against residual gas

accumulation. Failure to allow proper ventilation may cause re

or explosion.

Do not use fuel such as charcoal briquettes in gas grills.•

Gas sources to the grill must be regulated. Do not operate grill if•

regulators have been removed, re or explosion can occur.

Never leave the grill burners unattended when in use.•

Do not use water on grease res. Never pick up a aming pan. •

Turn the appliance off and smother the aming pan with a tight-

tting lid, a cookie sheet or a at tray. For aming grease outside

of the pan, smother it with baking soda or use a dry chemical or

foam-type re extinguisher.

Never allow clothing, pot holders or other ammable materials • come in contact with or be close to any grate, burner or hot

surface until it has fully cooled. Never wear loose tting or hanging

Safety Instructions

2009 G3, G4, G5 Grills

LTR20091050, Rev. A

www. c a l s p a s . c o m

garments while using your grill. Fabric may ignite and result in

personal injury.

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.

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 heat any unopened glass or metal container of food on• the grill. Pressure may build up and cause the container to burst,

possibly resulting in serious personal injury or damage to the grill.

Do not reach over your grill or any other surfaces when hot or in• use.

Maintenance and Repair

Spiders and other i• nsects can nest in the burners of the grill and

block the gas and airow to the burner ports. This creates a

dangerous condition that can result in a re behind the valve panel.

Inspect and clean the burners periodically and follow the guidelines

in the Cleaning and Maintenance section of this manual.

Unless specically recommended in this manual, do not repair or •

replace any part of the grill. A qualied technician should perform

all service. Any repairs made by a non-LMS approved dealer

technician will void your warranty.

Storage

When your gas grill is not in use, turn off the gas at the supply• cylinder.

Storage of a grill indoors is permissible only if the supply• cylinder

is disconnected and removed.

Precautions Regarding Children

Never leave children unattended in the area where the grill is• being used. Close supervision of children is necessary when any

appliance is use near children.

Do not store items of interest to children around or below the• grill.

Never allow children to sit or stand on any part of the grill.•

Installation / Assembly

2009 G3, G4, G5 Grills

LTR20091050, Rev. A

www. c a l s p a s . c o m

Most cities and counties require permits for exterior construction and

electrical circuits. In addition, some communities have codes requiring

residential barriers such as fencing and/or self-closing gates on

property to prevent unsupervised access to the property by children

under the age of ve. Your dealer can provide information on which

permits may be required and how to obtain them prior to the delivery

of your equipment.

We recommend the installation, adjustment and service of your new

grill be performed by LMS qualied installers and service technicians to

ensure proper operation and prevent accidents.

When planning your Cal Flame grill location, access to a gas line

should be considered. The location with the shortest gas line run is

recommended.

Whendetermininga suitable location,considerfactors suchasexposure

to wind, proximity to trafc paths, and windows that open into the

home.

Locate the barbecue grill only in a well-ventilated area and only on a

solid, at foundation (e.g. deck or cement slab).

If you do not have an updated ller valve on your existing propane tank,

you will need to purchase one at your local hardware store. Without it

you will not be able to attach your tank to your Cal Flame grill or rell

the tank at your local propane rell station.

Installation / Assembly

Converting Gas Grills

IMPORTANT: Cal Flame G3, G4, and G5 grills are manufactured to

operate on liquid propane (LP). However, they 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.

Ownersmust notconverttheir grills themselves.Attempting

to convert the grill from LP to NG may result in serious injury

and will void the warranty coverage.

Installation / Assembly

2009 G3, G4, G5 Grills

LTR20091050, Rev. A

www. c a l s p a s . c o m

Cabinet Cut-out Dimensions

Your Cal Flame grill is designed for easy installation into a non-

combustible enclosure. The supporting deck or counter must be at

and level. When determining the nal location of your grill, adequate

cross ventilation must be present to prevent gas from being trapped

in the event of a leak.

The drawings below show the different types of cabinet cut-out

dimensions for gas grills and accessories.

Grill Model Width Depth Height

G3 Three Burner 23 ¼” 22 ¼” 9 ¼”

G4 Four Burner 30 ¾” 22 ¼” 9 ¼”

G5 Five Burner 38 ¼” 22 ¼” 9 ¼”

WIDTH DEPTH

HEIGHT

Installation / Assembly

2009 G3, G4, G5 Grills

LTR20091050, Rev. A

www. c a l s p a s . c o m

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.

Thegrillunitmustbeusedwiththegaspressureregulator.Theregulator

will control and maintain a uniform gas pressure in the manifold. The

burner orices have been sized for the gas pressure delivered by the

regulator.

WARNING: Attempting to operate the grill unit without the gas

regulator installed could cause an explosion and possible death.

Cylinder Specication

Any LP gas supply cylinder used with this grill must be:

Constructed and marked in accordance with the• Specications

for LP-Gas Cylinders of the U.S. Department of Transportation

or the National Standard of Canada, CAN/CSA-B339, Cylinders,

Spheres and Tubes for Transportation of Dangerous Goods;

and Commission, as applicable.

Approximately 12 inches in diameter and 18 inches high.•

Installation / Assembly

2009 G3, G4, G5 Grills

LTR20091050, Rev. A

www. c a l s p a s . c o m

The maximum fuel capacity is 20 lbs. of propane, or 5 gallons. Full

cylinder weight should be approximately 38 lbs. (43.7 lbs. nominal

water capacity.) Never ll the cylinder beyond 80% full.

Place the dust cap on the cylinder valve outlet whenever the cylinder is

not in use. Only install the type of dust cap on the cylinder valve outlet

that is provided with the cylinder valve. Other types of caps or plugs

may result in leakage of propane.

LP Gas Hook Up

An enclosure for an LP gas cylinder shall be vented by openings at the

level of the cylinder valve and at oor level. The effectiveness of the

openings for purposes of ventilation shall be determined with the LP-

gas supply cylinder in place. This shall be accomplished in one of the

following manners:

One side of the enclosure shall be completely open.1.

Enclosures that have four sides, complete with a top and bottom:2.

At least two ventilation openings at cylinder valve level shall bea. provided in the sidewall, equally sized, spaced at 180º (3.14

rad), and unobstructed. Each opening shall have a total free

area of not less than one square inch per pound (7.1 cm²/kg)

of stored fuel capacity, and not less than a total free area of 10

square inches (64.5 cm²).

Ventilation openings shall be provided at oor level and shall b. have a total free area of not less than one square inch per

pound (7.1 cm²/kg) of stored fuel capacity and not less than

a total free area of 10 square inches (64.5cm²). If ventilation

openings at oor level are in a sidewall, there shall be at least

two openings. The bottom of the openings shall be at oor

level and the upper edge no more than 5 inches (127 mm)

above the oor. The openings shall be equally sized, spaced at

180º (3.14 rad) and unobstructed.

Every opening shall have minimum dimensions so as to permitc. the entrance of a 1/8 inch (3.2 mm) diameter rod.

Transporting and Storing LP Gas

Transport only one cylinder at a time. Ensure the cylinder is secured in

an upright position with the control valve turned off and the dust cap

in place. Store cylinders outdoors and out of reach of children. Do not

store cylinders in a building, garage, or any other enclosed area.

Installation / Assembly

2009 G3, G4, G5 Grills

LTR20091050, Rev. A

www. c a l s p a s . c o m

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.

A licensed contractor or local gas company representative must perform

all natural gas connections.

Ensure that the service supplying the grill is tted with a shut off valve

conveniently positioned near the grill and giving ease of access.

The grill must be isolated from the gas supply piping system by closing

its individual manual shutoff valve during any pressure testing of the

gas supply piping system at test pressures equal to or less than 0.5 psi

(3.5 kPa).

The grill and its individual shutoff valve must be disconnected from the

gas supply piping system during any pressure testing of that system at

test pressure in excess of 0.5 psi (3.5 kPa).

Your Cal Flame grill for use with natural gas comes equipped with its

own regulator that MUST NOT be removed. If this regulator needs to be

replaced, use only the type specied by Cal Flame for this appliance.

Connection

Remove the rear panel from the barbecue to gain access to the1. regulator and gas connection point.

Connect a suitable ex connector to the grill regulator.2.

Check the grill controls to ensure all control valves are in the full3. OFF position.

Turn on the main gas supply and check all connections for leaks4. using soapy water as described in the leak testing procedure

section.

Warning: If you see bubbles in the soapy solution at any of the

connections, turn off the gas supply and tighten the connection. If

tightening the connection does not seal the leak, it may be necessary

to replace the ex hose.

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