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4
Installation / Assembly
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 five. 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 qualified 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.
When determining a suitable location, consider factors such as exposure to wind, proximity to traffic paths, and windows that open into the home.
Locate the barbecue grill only in a well-ventilated area and only on a solid, flat foundation (e.g. deck or cement slab).
If you do not have an updated filler 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 refill the tank at your local propane refill station.
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.
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. www.calspas.com
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
Cabinet Cut-out Dimensions
Your Cal Flame grill is designed for easy installation into a noncombustible enclosure. The supporting deck or counter must be flat and level. When determining the final 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
5
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
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.
WARNING: Attempting to operate the grill unit without the gas regulator installed could cause an explosion and possible death.
Cylinder Specification
Any LP gas supply cylinder used with this grill must be:
•
•
Constructed and marked in accordance with the
Specifications 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.
www.calspas.com
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
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 fill 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 floor level. The effectiveness of the openings for purposes of ventilation shall be determined with the LPgas supply cylinder in place. This shall be accomplished in one of the following manners:
1.
2.
One side of the enclosure shall be completely open.
Enclosures that have four sides, complete with a top and bottom: a. b. c.
At least two ventilation openings at cylinder valve level shall be 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 floor level and 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 (64.5cm²). If ventilation openings at floor level are in a sidewall, there shall be at least two openings. The bottom of the openings shall be at floor level and the upper edge no more than 5 inches (127 mm) above the floor. The openings shall be equally sized, spaced at
180º (3.14 rad) and unobstructed.
Every opening shall have minimum dimensions so as to permit 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.
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
7
8
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 fitted 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 specified by Cal Flame for this applianc e.
Connection
1. Remove the rear panel from the barbecue to gain access to the regulator and gas connection point.
2.
3.
Connect a suitable flex connector to the grill regulator.
Check the grill controls to ensure all control valves are in the full
OFF position.
4. Turn on the main gas supply and check all connections for leaks 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 flex hose.
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2009 G3, G4, G5 Grills
LTR20091050, Rev. A
Leak Testing Procedure
Perform a leak test at least once a year whether the gas supply cylinder has been disconnected or not. In addition, whenever the gas cylinder is connected to the regulator or whenever any part of the gas system is disconnected or replaced, perform a leak test.
As a safety precaution, remember to always leak test your grill outdoors in a well-ventilated area. Never smoke or permit sources of ignition in the area while doing a leak test. Do not use a flame, such as a lighted match to test for leaks. Use a solution of soapy water.
1. Prepare a leak testing solution of soapy water by mixing in a spray bottle one part liquid soap to one part water.
2.
3.
Make sure all the control knobs are in the OFF position.
Turn on the gas.
a. b.
On
On natural gas systems, turn the main feed valve to the grill.
LP systems, turn the cylinder valve knob counter clockwise one turn to open.
4.
5.
Apply the leak-testing solution by spraying it on joints of the gas delivery system. Blowing bubbles in the soap solution indicates that a leak is present.
Stop a leak by tightening the loose joint or by replacing the faulty part with a replacement part recommended by the manufacturer.
Do not attempt to repair the cylinder valve if it is damaged. The cylinder must be replaced.
6. Turn all control knobs back to the full OFF position.
If you are unable to stop a leak:
1.
2.
Turn all control knobs back to the full OFF position.
Shut off the gas supply to the grill and release pressure in the hose and manifold by pushing in and turning any of the control valves one quarter turn counter-clockwise.
3.
4.
On LP systems, remove the cylinder from the grill.
Call an authorized gas appliance service technician or an LP gas dealer.
Do not use the appliance until the leak is corrected.
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
www.calspas.com
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10
Installing the Grill in a
Barbecue Island
You will need a second person to help you to avoid damaging the grill or your barbecue island.
Before installing a grill 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.
Pay careful attention to the location of the gas line. It should be routed away from sources of heat and should make as few bends as possible.
Check to see if the gas line connection will be accessible when grill is installed.
• If the gas line connection is not easily accessible when the grill is installed, support the grill above counter level and attach the gas line to the grill. When the gas connection is made, slide the grill into the cut out.
• If the gas line connection is accessible when the grill is installed, slide the grill into the cut out and then attach the gas line.
Be very careful not to kink the gas line when lowering the grill into the cut out.
Keep your fingers away from where the grill will be supported on counter. Your fingers could become trapped and serious injury could occur.
Check to make sure the grill is level and is supported around the entire outside edge. If the grill is not level or is unstable, use noncombustible shims under the outside lip to stabilize it.
Perform the leak test procedure as described earlier in this manual.
www.calspas.com
2009 G3, G4, G5 Grills
LTR20091050, Rev. A
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