Calflame Chef C100 User manual

2002 Owner’s Manual
USA and Canada
Chef Series
Master Chef Series
Gourmet Series
Duplication without written consent is strictly prohibited.
This owners manual is for BBQ Grills and Outdoor Kitchens
Manufactured after March 1, 2002 Sold and Delivered in USA and
Canada
Due to our continuous improvement program, all models, operation, and/or specifications are subject to
change without prior notice.

Welcome
To The Cal Spas Family
Congratulations on the purchase of your new Cal Flame BBQ. Welcome to our
family. You can feel confident knowing that you have purchased on of the
most technologically advances outdoor cooking environment in the industry.
Your new Cal Flame BBQ is backed by the world wide recognized name in
value, reliability and customer service, Cal Spas.
Customer Infromation:
We want to learn more about you. After reading this manual, please complete
and submit the attached Customer Survey and Warranty Registration Card or
register online at CalSpas.Com. Your feedback will be used to help us serve
you, our valued customer better, and register your new outdoor kitchen
warranty.
Cal Spas has been manufacturing home resort products since 1979, and is
considered a pioneer and leader in the industry. Through our State-of -the-Art
manufacturing facility in Pomona, California, we manufacture not only world
class outdoor kitchens, but also an entire line of home resort products. Those
products include, but are not limited to Spas, Gazebos, Saunas, jetted
bathtubs, billiard tables, and much, much more. Cal Spas is devoted to
bringing you a total environment of peace, tranquility, and pure enjoyment with
extensive line of Home Resort Products.
Cal Spas Information:

Table of Contents
Safety:
Safety Instructions.....................................00
Insect Warnings.........................................00
Before Using You Grill
Customer Information
Model and Serial Location
Installation:
Installation Location
Built-in Installation
Built-In Designs
Cabinet Cutout Design
Gas Requirements
Side Burner Attachment
Access Door
Adjustments and Efficiency
Air Shutter Adjustment
Low Setting Adjustment for
grill and open burners......................................
Leak Testing
Leak Test Procedure
Heat Deflector
Operation:
Grill Features
Grilling
Grill Operation
Grill Lighting
Manually lighting the grill
Rotisserie Operation
Manually lighting the
nfrared Rotisserie Burner..................................
Lighting side burner
Manually lighting side burner
Flame height
Cleaning and Maintenance:
Racks.....................................00
Drip Trays.........................................00
Stainless Steel
Grill Burners
Heat Deflector
Firebox Bottom
Troubleshooting:
Troubleshooting
Customer Service:
Customer Service contact

WARNINGS AND NOTICES
General Safety Requirements:
1. Installation of this appliance must conform
with local codes and with either the National
Fuel Gas Code, ANSI Z223.1, or CAN/CGA-
B149.1, Natural Gas Installation Code or
CAN/CGA-B149.2 Propane Installation Code.
2. The utilization of an external electrical
source requires that when installed, this gas
appliance must be electricaly grounded in
accordance with local codesand the National
Electrical Code ANSI/NFPA 70, or in Canada
CSA C22.1.
3. This grill and side burner and inline shut off
valve must be disconnected prior to perform-
ing any pressure testing of gas line above 1/2
psi (3.5kPa),
4. When using a self-contained LP-gas sup-
ply system, make sure that the tank is
properly marked with with either the U.S.
Department of Transportation (DOT) or
National Standards of Canada CAN/CSA-
B339
5. WARNING:
California Proposition 65:
The burning if gas cooking fuel generates
some byproducts that are on he list of
substances which are known by the State of
California to cause cancer of
reproductive harm.
To minimize exposer to these substances,
always operate this unit as described in this
manuals and only operate in well ventilated
areas.
WARNING:
Use of this product in any other way than
described in this manual, may result in fire
or explosion, causing property damage,
personal injury or even death.
WARNING:
Always have a licensed electrician and
contractor install electricaland gas lines.
Incorrect instalation in either case may
result in fire or explosion, causing property
damage, personal injury or even death.
IF YOU SMELL GAS:
1. Shut off gas to grill
2. Extinguish any open flame
3. Open lid
4. If oder persists, immediately call
your gas supplier or your fire
department
DO NOT TRY TO FIX THE
PROBLEM YOURSELF.

Customer Information
Locating Products Serial Number:
Your new Cal Flame BBQ’s serial number is located on a metal plate inside the door
below the grill on the floor. You will need this number to properly register you BBQ and
activate
warranty coverage.
Please write this number is the space provided in the back of this manual for future ref-
erence.
Warranty Registration:
It is very important to properly register you BBQ’s warranty. As mentioned on the
previous pages, you can do this two ways. You may register at Calspas.com or
complete the enclosed Customer Survey and Registration Card. Each will only take a
few minutes of your time and ensure that your purchase is registered. With this
information we are able to activate your warranty and be able to offer assistance in the
future for parts and accessories ordering.

SAFETY INSTRUCTIONS
Please read before installing and operating your new Cal Flame Grill
1. Your new gas grill should be professional installed by a licensed contractor.
Refer to the instruction in this manual to ensure proper and safe installation and
operation.
3. Have a qualified technician or installer adjust your grill for the type of gas
(Natural or Propane).
2. Ask installer of the location of the shut-off valve.
Note: All gas line are required to have their own shut-off valve readily available
4. If you smell gas:
4.1 Shut off gas to grill
4.2 Extinguish any open flame
4.3 Open lid
4.4 If oder persists, immediately call your gas supplier or your fire
department
DO NOT TRY TO FIX TH E PROBLEM YOURSELF.
5. Caution:
To prevent fire and smoke damage, remove all pakaging mateial before
operating grill.
6. Before starting to cook:
Clean the grill thoroughly with hot, soapy water. This is necessary to remove
residuals and solvents used at the factory to clean and remove dirt, oil and grease
which may have remained from the manufacturing process. The grates should
thoroughly cleaned.
7. 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; follow
guidelines in Cleaning and Maintenance on page 26.

SAFETY INSTRUCTIONS
(continued)
8. In the event a burner goes out and gas escapes, turn off burner knobs, open fully
the grill hood and let the air out. Do not attempt to use the appliance until the gas
has had time to dissipate.
9. Unless specifically recommended in this manual, do not repair or replace any part
of the grill. A qualified technician should perform all other service. Warranty service
must be performed by an authorized service agency.
10. Never grill without the drip pan in place and pushed all the way to the back of
the grill. Without it hot grease could leak downward and produce a fire or explosion
hazard.
11. Keep any electrical supply cord, or the rotisserie motor cord away from the heat-
ed areas of the grill.
12. Never use the grill 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 page 6.
13. The area surrounding your new grill should be kept clean, and free from flamma-
ble liquids and other combustible materials such as mops, rags, brooms, etc., as
well as solvents, cleaning fluids, and gasoline.
14. Do not use the grill or open burners as a storage area for flammable or plastic
items, which may ignite. Do not store spare LP cylinder or flammable materials in
the cart or under a built-in location. An LP cylinder not connected for use should not
be stored in the vicinity of this or any other appliance.
15. Never line surface burners with tin foil.
16. When the unit is not in use and connected to a self-contained LP-gas supply
system, the gas must be turned off at the supply cylinder.
17. When not in use it is permissible for a self-contained LP-gas outdoor appliance,
to be stored indoors only if the cylinder is disconnected and removed. Cylinders
must be stored outdoors out of the reach of children and must not be stored in a
building, garage or any other enclosed area.

SAFETY INSTRUCTIONS
(continued)
18. Never locate this appliance under an overhead, unprotected combustible con-
struction or enclosed area such as a garage, shed, or breezeway. Keep clear of
trees and shrubs.
19. This outdoor gas cooking appliance is not intended to be installed in or on recre-
ational vehicles and/or boats.
Precautions Regarding Children
1) Never leave children unattended in the area
where the grill is being used.
2) Do not store items of interest to children
around or below the grill, in the cart or masonry
enclosure.
3) Never allow children to sit or stand on any
part of the grill or to crawl inside a cart or
enclosure.
Use Precautions
1) Never leave the grill and top burners
unattended while using high flame settings.
Boilovers cause smoking, and greasy boilovers
may ignite.
2) Always use the proper size pan. Select
utensils with flat bottoms large enough to cover
the burner. The use of undersized utensils
exposes the sides of the utensils to direct con-
tact 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.
3) 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.
4) Do not use water on grease fires. Never
pick up a flaming pan. Turn appliance off and
smother the flaming pan with a tight-fitting lid,
cookie sheet or flat tray. For flaming grease
outside of the pan, smother with baking soda,
or use a dry chemical or foam type fire
extinguisher.
5) Never let clothing, potholders or other flam-
mable materials come in contact with or too
close to any grate, burner or hot surface until it
has cooled. Fabric may ignite and result in
personal injury.
6) When using the grill, do not tough the grill
rack, burner grate or immediate surroundings
as these areas become extremely hot and
could cause burns.
7) Proper apparel is a safety consideration.
Never wear loose fitting or hanging garments
while using your new grill.

SAFETY INSTRUCTIONS
(continued)
8) 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
could cause burns from steam.
9) Do not heat any unopened glass or metal
container of food on the grill. Pressure may
build up and cause the container to burst
resulting in serious harm or damage to the grill.
10) Do not use charcoal in the grill.
SAVE THIS MANUAL
FOR FUTURE
REFERENCE

INSTALLATION OF YOUR NEW GRILL
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 qualified
installers and service technicians. This is necessary to insure proper operation and also to
prevent accidents.
Location
When determining a suitable location take into account concerns such as exposure to wind,
proximity to traffic paths and keeping any gas supply lines as short as possible. Locate the
grill only in a well ventilated area.
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 loca-
tion for your grill it is required that ventilation holes be provided in the enclosure so that gas
will not become entrapped in the event of a leak (See page 9).
Built-in Design Models
If using a rear wall, locate the weatherproof electrical outlet on the left-hand side for the
rotisserie motor. The rotisserie motor requires a 110/120-volt 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
Side Burner

INSTALLATION OF YOUR NEW GRILL
(continued)
Gas Requirements
Your new grill is designed to work with either Natural Gas or with LP (Liquid Propane) Gas.
Check your rating plate to make sure the gas supply you are hooking up to is the gas type
the grill is manufactured for (see page 3).
An installer supplied gas shut-off valve must be installed in an easily accessible location.
Only use pipe sealant that is an approved type and is resistant to the actions of LP gas.
IMPORTANT: Your new grill will work either LP or Natural gas. You cannot switch gas
types without converting your valves and burners. Connecting the wrong gas type to
your grill may cause serious injury and damage your grill. Please ensure your are
connecting the proper gas type to your grill.
LP Gas Hook Up

NOTE: An enclosure for an LP gas cylinder shall be vented by openings on the level
the cylinder valve and at floor level. The effectiveness of the opening(s) for
purposes of ventilation shall be determined with the LP-gas supply cylinder in
place. This shall be accompanied by one of the following:
a. One side of the enclosure shall be completely open; or
b. For an enclosure having four sides, a top and a bottom:
1. At least two ventilation openings at cylinder valve level shall be provided in the
sidewall, equally sized, spaced at 180 degrees (3.14 rad), and unobstructed.
Each opening shall have a total free area of not less that ½ 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).
2. Ventilation opening(s) shall be provided at floor level and shall have a total
free area of not less than ½ 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 180 degrees (3.14 rad) and unobstructed.
3. Every opening shall have minimum dimensions so as to permit the entrance of
a 1/8 inch (3.2 mm) diameter rod.

Gas Manifold Pressure
Transporting the LP Gas Supply Cylinder
Cylinder Specification
Gas Pressure Regulator
Gas Supply Pressure
For natural gas, standard orifices are set for 4" W.C. (Water Column). A natural gas pres-
sure regulator is provided. For propane (LP) gas, standard orifices are set for 10" W.C. A
propane gas regulator with hose attachment for LP cylinder is provided. For plumbed-in LP
installation, use the convertible regulator and set it for LP gas.
Maximum line pressure (before the regulator) for Natural gas and plumbed-in Progane is
14" W.C., ½ psig (3.5 kPa).
Maximum line pressure for Natural Gas is 7" W.C. Minimum line presure for propane is 11"
W.C.
The unit must be used with the gas pressure regulator. The regulator will control and main-
tain a uniform gas pressure in the manifold. The burner orifices have been sized for the
gas pressure delivered by the regulator.
Any LP gas supply cylinder used with this grill must be approximately 12 inches in diameter
and 18 inches high. 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.) Always
use the cylinder dust cap on the cylinder valve outlet during transport and when the cylinder
is not connected to the grill.
Only one cylinder should be transported at a time. Transport cylinder in an upright and
secure manner with control valve turned off and the dust cap in place.

INSTALLATION OF YOUR NEW GRILL
(continued)
1) Install side burner into an area of 17-
1/2 long, 11 inches wide and 3 inch
es deep.
2) 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.
3) Install the pipe tee assembly to the
grill intake pipe with pipe sealant.
Tighten assembly and align the
branch opening of the tee to the hole
of the cabinet.
4) Connect the flexible hose (male end)
to the pipe tee with pipe sealant.
5) Install and secure the Side Burner
into the island by simpley setting in
place.
6) Connect the female end of the
flexible hose to the side burner
intake pipe with pipe sealant.
6) Connect gas supply to the grill fol
lowing the instructions on page 8.
7) Check for gas leaks using soap
water solution. (1 part liquid soap, 3
parts water)

INSTALLATION OF YOUR NEW GRILL
(continued)
1. Provide cut out and door jamb with
inside dimensions as follows:
19 3/8" X 28 3/8" for DAD-30 and
19 3/8" X 40 3/8" for DAD-48
2. Check fitting of frame against cutout.
Mark location of rivet nuts.
3. Chisel material out to clear space for the
rivet nuts. (See figure 1)
4. Secure the steel frame with 16 screws of
type #10 X ¾ truss head phillips S/S.
5. Attach doors to frame.
Installing Access Doors
6. Adjust doors as follows:
a) For height adjustment, loosen the
two screws attached to each
mounting plate.
(See figure A)
b) Snap off hinge and secure mounting
plate with #6 X 1 flat phillips S/S.
(See figure B).
c) For side adjustment turn screw to
increase or decrease door overlay.
(See figure C)
d) For depth adjustment, loosen screw,
adjust door to desired position and
retighten screw.
(See figure D)

IAdjustments and Efficiency
INSTALLATION OF YOUR NEW GRILL
(continued)
Prior to shipment each burner is tested and
adjusted at the factory. Due to variations in
the location, conditions, gas supply or when
converting from one gas to another,
readjustment of the burners may be
necessary.
The flames of the burners (except the
rotisserie burners) should be visually
checked and compared to that of the figure
on the right.
Flames should be blue and stable with no
yellow tips, excessive noise or lifting. If any
of these conditions exist, check if dirt,
debris, spider webs, etc. block the air
shutter or burner ports. Proceed with air
shutter adjustment.
“Insert Cad drawing
showing proper grill
burner flame height”
Air Shutter Adjustment
A sheet metal disk known as an air shutter governs
the amount of air entering the burner. It is locked in
place by a setscrew, which must be loosened with a
screwdriver prior to lighting the burner.
1. To access the grill burner air shutters, set all the
knobs in the off position and remove them. Now take
out the valve panel by first removing four screws.
Pull the valve panel outwards while unplugging the
cables attached to the rotary igniter.
2. With a screwdriver, loosen the lockscrew on the
face of the air shutter.
3. Light the burner. For the following instructions be
careful as the burner may be very hot.
“Insert Cad
drawing
showing air
shutter
adjustment”

Air Shutter Adjustment
(continued)
4. Notice the flame characteristics. If the flame is yel-
low, indicating insufficient air, turn the air shutter
counter clockwise to allow more air to the burner.
5. If the flame is noisy and tends to lift away from the
burner, indicating too much air, turn the air shutter
clockwise.
6. Repeat procedure for each burner requiring adjust-
ment. Be sure to tighten air shutter screws when fin-
ished.
7. Once adjusted, turn the burner OFF and reverse
steps to reassemble.
Low Setting Adjustment
Grill and Open Burners
The valves on your new grill feature an adjustable low
setting. Due to fluctuations in gas pressure, heating
value or gas conversion, you may feel it necessary to
increase or decrease gas flow in the low position.
1. Begin by lighting the burner.
2. Turn the control knob to the lowest setting, all the
way counter clockwise. The arrow will stop between
MED and LOW.
3. Remove knob.
4. Hold the valve shaft with a pair of pliers and insert
a thin, flat tipped screwdriver into the shaft. While
viewing the burner, adjust to a minimum stable flame.
5. WARNING! Look for stability in the low flame set-
ting. A too small burner flame may go out or be extin-
guished easily. Unburned gas can then escape creat-
ing a hazardous condition.
NOTE: It is normal to hear a popping sound when the
burners are first turned OFF.
“Insert Cad
drawing
showing bezel
and valve stem
adjustment”

INSTALLATION OF YOUR NEW GRILL
(continued)
Leak Testing
Perform a leak test at least once each year whether the gas supply cylinder has
been disconnected or not. In addition, anytime the gas cylinder is connected to
the regulator or any part of the gas system is disconnected or replaced, conduct
the leak testing. This applies to natural gas as well as LP Gas.
As a safety precaution, remember to always leak test your grill outdoor 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 only a leak testing solution as specified below.
1. Prepare a leak testing solution of sudsy water by
mixing in a spray bottle half-liquid soap and half
water.
2. Check and make sure all the control knobs are in
the OFF position.
3. Turn cylinder valve knob counter clockwise one
turn to open.
4. Apply leak-testing solution by spraying on joints of
the gas delivery system.
5. Blowing bubbles in the soap solution indicates that
a leak is present.
6. Stop a leak by tightening the loose joint or by
replacing the faulty part with a replacement part rec-
ommended by the manufacturer. Do not attempt to
repair the cylinder valve if it should become damaged.
The cylinder must be replaced.
Leak Testing Procedure

7. If you are unable to stop a leak, shut off the gas
supply at the cylinder valve. Remove the cylinder
from the grill. Call an authorized gas appliance serv-
ice technician or LP gas dealer. Do not use the appli-
ance until the leak is corrected.
8. Push in and turn any control knob to release pres-
sure in the hose and manifold.
9. Turn off the control knob.
Leak Testing Procedure
(continue)
Installing the Heat Deflector
The Heat Deflector should be fully inserted in its
position, as shown, before using the grill.
“Insert Cad drawing showing
heat reflector”