Calflame G3 User manual

Copyright 2008-2009 LMS, Inc. All rights
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: [phone]
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
1
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.

2
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
3
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.•

4
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
5
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

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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
7
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.

8
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.