Calflame 2005 Spa User manual

LTR20051000, Rev D
7/21/2005

2005 Spa Owner's Manual Page ii
CONTACT INFORMATION
For customer service, please contact your authorized dealer
immediately. If you need additional information and/or
assistance, please contact:
C.A.I. Customer Service Department
1462 East Ninth Street
Pomona, CA 91766
Toll Free: 1-800-CAL-SPAS
Fax: [phone]
www.calspas.com
Copyright 2004, 2005 California Acrylic Industries, Inc. All rights reserved. Duplication without
written consent is strictly prohibited.
Cal Spas™, Adjustable Therapy System™, ATS™, Bio-Clean™, Cal Balance™, Cal
Entertainment System™, Cal Zone Quest 1000™ and Cal Zone Quest 2000™, Cal Sweep™, Cal
Select™, Fitness Spa Series™, Spa Cal™, and XL Heat Exchanger are registered trademarks.
Due to continuous improvement programs, all models, operation, and/or specifications are
subject to change without prior notice.
LTR20051000, Rev D
7/15/2005
7/21/2005

Table of Contents
2005 Spa Owner's Manual 7/21/2005
Read This First!
General Safety Precautions ................................................................................... 1
Precautions Regarding Children ............................................................................ 2
Other Common Sense Precautions ....................................................................... 2
What To Do If You Smell Gas................................................................................ 3
Delivery and Set-Up
Planning the Best Location For Your Barbecue..................................................... 4
Liquid Propane Gas Requirements........................................................................ 7
Natural Gas Requirements .................................................................................... 9
Assembly and Installation
Infrared Burners ................................................................................................... 10
Barbecue Island Sections .................................................................................... 11
Granite Kit Instructions......................................................................................... 14
Barbecue Cart End Shelves................................................................................. 15
Modular Carts....................................................................................................... 15
Side Burners ........................................................................................................ 16
New Access Doors............................................................................................... 17
Griddle and Griddle Storage ................................................................................ 18
G3000 Island / Sports Bar Canopy ...................................................................... 19
Operating Your Barbecue
Cal Flame Familiarization .................................................................................... 28
Operating the Grill ................................................................................................ 28
Cooking with the Rotisserie ................................................................................. 30
Cooking with the Convection 3000 Grill............................................................... 31
Turning on and off the Lights ............................................................................... 34
Charcoal Grill ....................................................................................................... 35
Griddle.................................................................................................................. 36
Drop-In Food Warmer .......................................................................................... 36
30” Warming Drawer ............................................................................................ 37
Canopy Waterfall and Barbecue Island Waterfall ................................................ 38
LED Lights............................................................................................................ 39

Table of Contents
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Operating the Cal Flame Entertainment Center
Splash Stereo System ......................................................................................... 40
Entertainment Systems........................................................................................ 40
Cal Flame Entertainment System Operation ....................................................... 43
Operating the DVD System In TV Mode.............................................................. 44
Cleaning and Maintenance
Cleaning Instructions............................................................................................ 46
Care of Stainless Steel Carts & Grills .................................................................. 51
Covering Your Stainless Steel Cart ..................................................................... 51
After Use Care ..................................................................................................... 51
Appendix
Troubleshooting Procedures................................................................................ 52
Parts List .............................................................................................................. 55
Warranty Information............................................................................................ 57

Read This First!
2005 Spa Owner's Manual Page 1
7/21/2005
Read This First!
YOU ARE RESPONSIBLE FOR ENSURING THAT A NATURAL GAS LINE IS INSTALLED AND SAFE
TO USE. WE HIGHLY RECOMMEND THAT YOU HAVE A LICENSED TECHNICIAN RUN ALL
NATURAL GAS LINES AND CONNECT ALL NATURAL GAS HOOK-UPS. CALIFORNIA ACRYLICS
INDUSTRIES (C.A.I.) WILL NOT BE HELD RESPONSIBLE IN ANY WAY FOR AN IMPROPERLY
CONNECTED GAS LINE.
THE LIGHTING INSTRUCTIONS FOR THE ISLANDS AND CARTS IS IDENTICAL. FOLLOW THESE
INSTRUCTIONS CAREFULLY, AS ANY DEVIATION MAY RESULT IN SERIOUS INJURY OR
POSSIBLY DEATH.
General Safety Precautions
Please read before installing and operating your new Cal Flame™ grill.
•Your new gas grill should be professionally installed by a licensed contractor. Refer to the instructions in
this manual to ensure proper and safe installation and operation.
•To prevent fire and smoke damage, remove all packaging material before operating grill.
•Before you start cooking,, clean the grill thoroughly with hot, soapy water. This is necessary to remove
residual solvents, oil and grease which may have remained from the manufacturing process. The grates
should also be thoroughly cleaned in the same manner.
•Spiders and other insects can nest in the burners of the grill and block the gas and airflow to the burner
ports. This creates a dangerous condition that can result in a fire from behind the valve panel. Inspect and
clean the burners periodically and follow the guidelines in the Cleaning and Maintenance section of this
manual.
•In the event that a burner goes out and gas escapes, turn off the burner knobs, open the grill hood fully and
let it air-out. Do not attempt to use the grill or any other island feature until the gas has had time to dissipate.
•Unless specifically recommended in this manual, do not repair or replace any part of the grill. A qualified
technician should perform all of the service. Any repairs made by a non- C.A.I. approved dealer technician
will void your warranty.
•Never use the grill without the drip pan in place, pushed all the way to the rack located just under the grill.
Without it, hot grease could leak downward and produce a fire or explosion hazard.
•Keep any electrical supply cord or the rotisserie motor card away from the heated areas of the grill.
•Never use the grill or side burner in windy conditions. If located in a consistently windy area (oceanfront,
mountaintop, etc.) a windbreak will be required. Always adhere to the specified clearances listed in this
manual.
•The area surrounding your new grill should be kept clean and free from flammable liquids and other
combustible materials such as mops, rags or brooms, as well as solvents, cleaning fluids, and gasoline.
•Do not use the grill as a storage area for flammable or plastic items, which may ignite. Do not store any
materials inside or near barbecue island. Do not store the liquid propane (LP) cylinder in the vicinity of this
or any other appliance when it is not being used.
•Never line the grill or side burners with aluminum foil.

Read This First!
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7/21/2005
•When the unit is not in use, be sure to turn off the gas at the LP tank.
•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.
Precautions Regarding Children
•Never leave children unattended in the area where the grill is being used.
•Do not store items of interest to children around or below the grill or island.
•Never allow children to sit or stand on any part of the grill or island.
Other Common Sense Precautions
•Never leave the grill and side burners unattended while using high flame settings. Boil-overs cause smoking
and greasy boil-overs may ignite.
•Always use the proper size pan. Select utensils with flat bottoms large enough to cover the burner. The use
of under-sized utensils exposes the sides of the utensils to direct contact with a portion of the flame. This
can scorch utensils and hamper cleanup. Excessive flames on large stainless steel pots can result in
permanent discoloration. For best results, we recommend commercial quality aluminum pans and utensils.
•Always position handles of utensils inward, so they do not extend over adjacent work areas or cooking
areas. This reduces the risk of burns, ignition of flammable materials, and spillage due to accidental contact
with the utensils.
•Do not use water on grease fires. Never pick up a flaming pan. Turn the appliance off and smother the
flaming pan with a tight-fitting lid, a cookie sheet or a flat tray. For flaming grease outside of the pan,
smother it with baking soda or use a dry chemical or foam-type fire extinguisher.
•Never let clothing, potholders or other flammable materials come in contact with or close to any grate,
burner or hot surface until it has cooled. 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.
•Proper apparel is a safety consideration. Never wear loose fitting or hanging garments while using your new
grill.
•Only use dry potholders - do not use a towel or other bulky cloth in place of potholders. Moist or damp
potholders 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 use charcoal in a gas grill or side burner.
•Do not attempt to move the stainless steel cart while it is hot or in use.
•It is extremely important to lock all caster wheels even on flat even surfaces.
•Do not lean, sit or stand on the stainless steel cart, including the foldout work surfaces.
•Do not exceed 50 pounds of weight on the foldout work surfaces.

Read This First!
2005 Spa Owner's Manual Page 3
7/21/2005
•Do not block the vents located in the cabinet area of your Cal Flame™ Island or stainless steel cart as gas
may build up in case of leak and cause serious damage.
•Your grill must be plugged into a permanent, grounded 110V outlet with a dedicated 15A GFCI breaker. Do
not use an extension cord to supply power to your Cal Flame™ Island, grill or cart. Such use may result in
fire, electrical shock or other personal injury. Do not install a fuse in the neutral or ground circuit. A fuse in
the neutral or ground circuit may result in an electrical shock hazard. Do not ground this appliance to a gas
supply pipe or hot water pipe. Keep any electrical supply cords and the fuel supply hose away from any
heated surfaces.
•Do not reach over your grill or any other surfaces when hot or in use.
What To Do If You Smell Gas
1. Shut off gas to grill.
2. Extinguish any open flame.
3. Open lid.
4. If odor persists, immediately call your gas supplier or your fire department.
DO NOT TRY TO FIX THE PROBLEM YOURSELF..

Delivery and Set-Up
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Delivery and Set-Up
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.
Safe and satisfactory operation of your new grill depends upon its proper installation. The installation,
adjustments and service of your new grill must be performed by C.A.I. qualified installers and service
technicians. This is necessary to ensure proper operation and prevent accidents.
Planning the Best Location For Your Barbecue
Location
Your barbecue is for outdoor use only!
When planning your Cal Flame™ Island or cart location, be sure to consider the shortest gas line run possible.
Also, take into consideration the necessity of having a 110V power source for use of your appliances (e.g.
lights, rotisserie, refrigerator, receptacles, etc.).
When determining a suitable location, take into account concerns such as exposure to wind, proximity to traffic
paths, and windows that open into the home.
Locate BARBECUE Islands grills and stainless steel carts in well ventilated areas, and only on solid, flat
foundations (e.g. cement slab or deck). Do NOT place barbecue islands / outdoor kitchens or stainless
steel carts on dirt or grass.
Built-in Installation
Your new grill is designed for easy installation into a non-combustible enclosure. The supporting deck and
counter must be level and flat. When determining the final location of your grill, provide ventilation in the
enclosure so that gas will not become entrapped in the event of a leak. Make sure that you have one vent placed
at floor level and the other at five inches above floor level.
Built-in Design Models
If using a rear wall, locate a weatherproof electrical outlet on the side of the grill that the rotisserie motor will be
located on. The rotisserie motor requires a 110/120V supply. The power supply cord on the motor is equipped
with a 3-prong (grounded) plug for protection against shock hazard. Do not cut or remove the grounding prong
from the plug.
Cabinet Cut-Out Dimensions for Gas Grill and Accessories
Safe and satisfactory operation of your new grill depends upon its proper installation. The installation,
adjustments and service of your new grill must be performed by C.A.I. qualified installers and service
technicians. This is necessary to ensure proper operation and prevent accidents.
Figure 1 through Figure 4 show the four different kinds of cut-outs, the appliances each cut-out will
accommodate, and the cut-out dimensions for each appliance.

Delivery and Set-Up
Figure 1
Model Hardware Cutout Dimension
Width (In) Depth (In) Height (In)
BARBECUE872 2 Burner Grill 23 1/2 22 1/2 9 1/4
BARBECUE873 3 Burner Grill 23 1/2 22 1/2 9 ¼
BARBECUE874 4 Burner Grill 30 3/4 22 1/2 9 1/4
BARBECUE874C 4 Burner Convection Grill 30 3/4 22 1/2 9 1/4
BARBECUE875 5 Burner Grill 38 1/4 22 1/2 9 1/4
BARBECUE875C 5 Burner Convection Grill 38 1/4 22 1/2 9 1/4
BARBECUE870 Charcoal Grill 30 3/4 22 1/2 9 1/4
BARBECUE898 Deluxe Single Side Burner 12 1/4 22 7 3/4
BARBECUE899 Deluxe Double Side Burner 12 1/4 22 7 3/4
12" Cocktail Center 12 1/4 22 7 3/4
18" Cocktail Center 17 1/4 24 10
Drop In Ice Chest 30 3/4 22 1/2 9 1/4
Drop In Food Warmer 12 1/4 22 7 3/4
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Delivery and Set-Up
Figure 2
Model Hardware Cutout Dimension
Width (In) Depth (In) Height (In)
BARBECUE874F 4 Burner Flat Drop In Grill 38 1/4 22 1/2 >18"
BARBECUE852 Drop In Standard Side Burner 11 1/4 17 3/4 >3 1/2"
Drop In Sink 14 14 >12"
Drop In Food Warmer 12 22 >7 3/4”
Figure 3
Model Hardware Cutout Dimension
Width (In) Depth (In) Height (In)
Propane Tank Access Door 14 1/2 16 1/4 20 1/4
Single Access Door 16 1/2 2 1/2 19 1/2
Double Access Door 28 1/2 2 1/2 19 1/2
2 & 3 Drawer Storage 10 1/2 19 3/4 17 1/4
One Big One Small Drawer 10 1/2 19 3/4 17 1/4
Griddle and Griddle Storage 13 1/2 19 2 1/2
Warming Drawer 28 3/4 21 10
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