Broilmaster S5 SERIES GRILL User Manual

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S5

SERIES GRILLS

(PROPANE GAS AND NATURAL GAS TYPES)

OWNER’S MANUAL

THESE GRILLS ARE FOR OUTDOOR USE ONLY.

IMPORTANT

READ THIS OWNER’S MANUAL CAREFULLY BEFORE INSTALLING OR USING THIS PRODUCT. INSTALLER SHOULD LEAVE THIS MANUAL WITH THE CONSUMER AND THE CONSUMER SHOULD RETAIN IT FOR FUTURE REFERENCE.

WARNING

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE INJURY OR PROPERTY DAMAGE. REFER TO THIS MANUAL. FOR ASSISTANCE OR ADDITIONAL INFORMATION CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

FOR YOUR SAFETY

IF YOU SMELL GAS:

1.SHUT OFF GAS TO APPLIANCE.

2.EXTINGUISH ANY OPEN FLAME.

3.OPEN GRILL LID.

4.IF ODOR CONTINUES, IMMEDIATELY CALL YOUR GAS SUPPLIER OR YOUR FIRE DEPARTMENT.

5.DO NOT TOUCH ELECTRICAL SWITCHES.

FOR YOUR SAFETY

1.DO NOT STORE OR USE GASOLINE

OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

2.AN LP CYLINDER NOT CONNECTED

FOR USE SHALL NOT BE STORED IN THE VICINITY OF THIS OR ANY

OTHER APPLIANCE.

B100029-1-0502

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CONTENTS

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GAS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GRILL LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ELECTRICAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ASSEMBLY AND INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 GRILL ASSEMBLY AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 IGNITOR LIGHTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MATCH LIGHTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 IF A BURNER DOES NOT IGNITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 PREHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 COOKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 LOW FLAME ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 BURNER AIR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CARE AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

REPAIR PARTS AND WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 18

INTRODUCTION

Congratulations! You have chosen the finest grill for your barbecuing pleasure. Please take the time to read through this entire manual before assembling your Broilmaster® gas grill. Outdoor cooking is an art you will master.

Your Broilmaster® grill is identified by its model number, serial number, and gas type on a product identification label located on the grill. Always reference the grill’s model number, serial number, and gas type when contacting your Broilmaster® dealer. Record information from label here for easy reference.

Model Number:

Serial Number:

Gas Type: NATURAL

 

PROPANE

 

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SAFETY

Both NATURAL gas and PROPANE (also known as LP) gas have a long history of safe use when rules listed below are followed. If they are not followed, there is a danger of fire, explosion or personal injury.

Installation must conform to local codes or, in the absence of local codes, with the National Fuel Gas Code ANSI Z223.1. In Canada, installation shall be in accordance with CAN/CGA-B149.2Propane Installation Code, orCAN/CGA-B149.1Natural Gas Installation Code, and local codes where applicable. Consult your local NATURAL gas company or PROPANE gas dealer for code regulations and recommended procedures.

Never use PROPANE gas in a grill designed for NATURAL gas or NATURAL gas in a grill designed for PROPANE gas. Please consult your local gas company for any questions about propane or natural gas. Propane Gas Grills

On PROPANE gas grills, use only the PROPANE gas cylinder (tank) recommended or supplied. Broilmaster’s PROPANE gas grills are for use with standard 20 pound PROPANE gas cylinders. DO NOT CONNECT A BROILMASTER PROPANE GAS GRILL TO A PROPANE GAS CYLINDER EXCEEDING 20 POUNDS CAPACITY. A cylinder of approximately 12-1/8”(30.8 centimeters) tall is the maximum size cylinder allowed. The LP gas supply cylinder to be used must be:

1.constructed and marked in accordance with the specifications for LP gas cylinder of the U.S. Department of Transportation (D.O.T.) or the National Standard of Canada, CAN/CSA-B339,

Cylinders, Spheres, and Tubes for Transportation of Dangerous Goods; and Commission as applicable.

2.provided with a listed overfilling prevention device;

3.provided with a listed safety device having direct access with the vapor space of the cylinder and

the cylinder supply system must be arranged for vapor withdrawal;

4.provided with a shutoff valve terminating in a valve outlet as specified in the Standard for Compressed Gas Cylinder Valve Outlet and Inlet Connections, ANSICGA-V-1;

5.provided with a plug to effectively seal off the cylinder outlet when the cylinder is being stored or transported;

6.provided with a collar to protect the cylinder valve.

Always use the pressure regulator and hose assembly supplied with each PROPANE gas grill. The pressure regulator has an outlet pressure of not more than 11 inches water column and is to be connected to the PROPANE gas cylinder’s female valve before the grill can be operated. Keep the pressure regulator’s fitting clean and free of nicks and scratches. A dirty, nicked or scratched fitting can cause a gas leak, resulting in an explosion or fire when connected to the PROPANE gas cylinder. Replacement parts must be as specified by the repair parts list or as specified by Broilmaster.

CAUTION: OPERATION OF A PROPANE GAS GRILL WITHOUT THE PRESSURE REGULATOR AND HOSE ASSEMBLY WILL CAUSE GAS LEAKS WHICH COULD CAUSE A FIRE, EXPLOSION OR PERSONAL INJURY.

NOTE: SOME VALVE AND TANK COMBINATIONS ARE NOT COMPATIBLE. CHECK WARNING TAG ON VALVE AND TANK; ALSO CHECK EXTERNAL THREADS OF FITTINGS. Broilmaster pressure regulator and hose assemblies are equipped for cylinders with a Type 1 cylinder connection device.

Handle PROPANE gas cylinders with care:

A.If the cylinder’s outlet valve is damaged, do not attempt to use or repair. The cylinder must be replaced.

B.DO NOT store a grill indoors unless the PROPANE gas cylinder is disconnected and removed from the grill. When the cylinder is installed on the grill they must be stored outdoors in a well-ventilatedarea.

C.Disconnected cylinders must have a threaded valve plug tightly installed and must not be stored in a build ing, garage or any other enclosed space. KEEP OUT OF REACH OF CHILDREN.

D.Do not apply heat directly to a PROPANE gas cylinder.

E.Always transport, store and use PROPANE gas cylinders in an upright secure position.

F.DO NOT carry PROPANE gas cylinders in the passenger area of a vehicle.

G.For PROPANE gas grills, have PROPANE gas cylinders filled by a qualified gas dealer; cylinders are to be filled by weight, to no more than 80% of physical capacity.

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Natural Gas Grills

NATURAL gas grills do not have a pressure regulator. Broilmaster Natural gas grills operate at a manifold pressure of 7 inches water column.

For NATURAL gas grills, contact your local gas company to have a gas supply line installed for the grill. For NATURAL gas grills installed on a cart, use Broilmaster’s NG12 twelve foot flexible hose and quick disconnect kit to connect the grill to a pre-installedgas supply line.

All Grills

Check for gas leaks, after connecting a PROPANE gas cylinder, when a cylinder has not been used recently, or when a grill is being used for the first time. Use soapy water to check for leaks. Refer to CHECKING FOR LEAKS at the end of the Installation section.

CAUTION: DO NOT USE CANDLES, MATCHES OR OTHER IGNITION SOURCES WHEN CHECKING FOR LEAKS. GASES ARE VERY FLAMMABLE AND, IN CERTAIN CONCENTRATIONS, EXPLOSIVE. CHECKING FOR LEAKS WITH AN OPEN FLAME MAY LEAD TO FIRE, EXPLOSION OR PERSONAL INJURY.

DO NOT use grill until all leaks are repaired. Always turn gas OFF at the valve on the PROPANE gas cylinder or, for NATURAL gas, at the supply line shutoff valve when grill is not in use.

Inspect grill’s hose before each use of the grill. If there is excessive wear, or the hose is cut, it must be replaced. Replace only with the hose assembly specified by the repair parts list or as specified by Broilmaster.

GRILL LOCATION

This grill was designed for outdoor use and should not be used in any building, garage or other enclosed area, nor is it intended for use in or on any recreational vehicle or boat.

Never use the grill under combustible materials. (carport, covered porch, patio umbrella, etc.)

Minimum clearance from sides of grill to combustible materials (walls, fences, etc.) must be at least 16 inches. Minimum clearance from back of grill must not be less than 18 inches.

CAUTION: IF THIS GRILL IS INSTALLED AND OPERATED AT CLEARANCES LESS THAN THOSE SPECIFIED BY THESE INSTRUCTIONS, THE POSSIBILITY OF A FIRE, PROPERTY DAMAGE OR PERSONAL INJURY MAY EXIST.

CAUTION: DO NOT INSTALL OR USE THIS GRILL IN ANY AREA WHERE EXPLOSIVE MATERIALS SUCH AS GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS ARE BEING USED OR STORED, THE FLAME PRODUCED BY THE GRILL IS EXPOSED AND FLAME CONTACT WITH ANYTHING EXPLOSIVE OR FLAMMABLE WILL RESULT IN EXPLOSION OR FIRE.

Keep area around grill clear. Do not obstruct grill’s combustion and ventilation air flow. Keep the ventilation opening(s) of the cylinder enclosure free and clear of debris. Make sure grill is level prior to use.

ASSEMBLY AND INSTALLATION INSTRUCTIONS

All Broilmaster grills require some assembly and installation. Some models require more than others. Some of the following assembly and installation instructions do not pertain to all grill models. Some grill models come equipped with accessories (i.e. side burner, cart, etc.) which were assembled and installed at the factory. Some grill models come with accessories (i.e. cart) which are ready to be assembled and installed. Follow the instructions provided with the accessory to complete it’s installation on a specific grill model.

PREPARATION

1.Before assembling the grill determine which post or cart the grill will be mounted on. See the enclosed “GRILL MOUNTING” sheet for mounting options. Obtain and assemble the desired mount (post or cart) per instructions furnished with it.

NOTE: If grill is to be mounted on anin-groundpost, the post shall be protected against corrosion as warranted by soil conditions. Corrosion protection shall be provided as needed with a suitable coating to retard the effects of corrosion conditions existing in local areas.

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2.Gather the following items. They will be needed for grill assembly and installation. Phillips Screwdriver

Two adjustable wrenches or a set of open end wrenches or a socket/ratchet set Soapy water solution (to test for gas leaks)

Pencil (to check off steps as completed)

3.Remove all loose parts from inside the grill carton and grill housing which are to be assembled and installed.

GRILL ASSEMBLY AND INSTALLATION

1.If the grill is to be mounted on a cart, assemble the cart as shown in figure 1A & 2 with #10-3/8"sheet metal screws.

2.Attach the valve to the control panel with two No. 10-24x 1/2" Phillips head screws. See figure 2A.

A.Push the gas knobs onto valve stems as shown by figure 2A. Turn knobs clockwise to OFF.

B.If the grill is furnished with a pushbutton ignitor, insert the ignitor into the ignitor hole of the control panel and then secure it to the control panel with a nut as shown by figure 4.

3.Install the Piezo Ignitor

A.If your grill is furnished with an ignitor, assemble the ignitor’s collector box as shown by figure 5. Caution: do not cut or damage the ignitor wire protruding from the collector box.

B.Install the collector box in the grill bottom thru the 15/32 hole located toward the front of the grill as shown in figure 5A. Flat washer, lock washer, 2 nuts align control panel with casting front and tighten nuts. See step 5 in Patio Base Instructions to hook up gas.

4.Insert 10-24x 3/4 bolt through 7/32" dia. hole located right of center towards rear of grill bottom. Attach speed nut and tighten. See figure 6.

5.Install Control Panel. Post Models Only.

A.For post models, route two 1/4-20x1-1/2"screws install flat washer, lock washer and nuts through two holes in bottom of the grill bottom and the top of the control panel. Align control panel with casting front and tighten nuts. See figure 3. See step 5 in Patio Base instructions for gas hook up.

6.Mount the grill per Figure 1 or Figure 2A.

A.If the grill is to be mounted on a post, mount the grill bottom to the prepared post assembly so the eyebolts will protrude through the holes at the corners of the rectangular opening in the grill bottom. Secure the grill bottom with four 1/4 shakeproof washers and four 1/4-20hex nuts. See figure 1.

B.For cart models, install the control panel between the cart angle brackets, and grill bottom. align holes. Insert four 1/4-20x1-1/2"screws, install flat washer, lock washer and1/4-20nut, then tighten. See figure 2A.

7.Attach the lid handle to grill lid using two No. 10-24x 3 1/2" carriage bolts, two handle spacers, two shakeproof washers and two No.10-24hex nuts. See figure 1 for cart installation.

8.Mount the grease tray as shown in figure 6. See Patio Base instructions for base installation.

A.Use the #10-24wing nut and 5/8" O.D. flat washer to attach the grease tray bracket to the screw installed in step 4. Do not tighten wing nut yet.

B.Place the provided aluminum grease tray in the bracket and adjust the bracket to align the tray with the grill’s grease drain hole in grill bottom.

C.Tighten the wing nut. When the grease tray is full replace with a new empty tray.

D.Mount grease cup assembly as shown in Patio Base Instructions (figure 6)

9.Attach side shelf, if included, using two 1/4-20x 1/2" hex bolts, 1/4 I.D. lock washers, and1/4-20hex nuts as shown by figure 7. Use the #8 x 1/2” sheet metal screw and the 1/4" x 5/16" O.D. spacer to keep the wood shelf from sliding.

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FIGURE 1

FIGURE 1A

 

 

 

INSTALL FRONT SCREWS FIRST

 

 

 

 

 

 

 

 

 

 

GRILL TO POST

 

 

 

 

 

CART ASSEMBLY

 

MOUNTING

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FIGURE 2

FIGURE 2A

 

 

 

CART

 

 

 

CONTROL PANEL ASSY.

 

 

 

 

 

ANGLE BRACKETS

 

 

 

TO CART

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FIGURE 3

 

 

FIGURE 4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

IGNITOR TO CONTROL PANEL

CONTROL PANEL ASSY. TO POST

 

 

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FIGURE 5

COLLECTOR BOX ASSEMBLY

(S5 MODEL ONLY)

FIGURE 5A

COLLECTOR BOX

INSTALLED

S5 MODEL

ONLY

FIGURE 7

SIDE SHELF ASSEMBLY

FIGURE 8

BURNER

INSTALLATION

FIGURE 9

VENTURI TUBE LOCATION

SPEED NUT

FIGURE 6

5/8 O.D. WASHER

GREASE CUP

INSTALLATION

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11.Install the burner as shown by figure 8 and figure 9.

A.Tilt the burner forward and guide its two venturi tubes through the rectangular hole in the bottom of the grill as shown by figure 9. CAUTION: During installation of the burner, care should be taken to not damage the grill’s ignitor wire.

B.Push the ends of venturi tubes onto the corresponding factory-installedgas orifices located beneath the grill. See figure 10.

C.Install ignitor wire, female end, by pushing it onto male ignitor, if equipped with piezo.

See Patio Base Instructions, step 8 for control housing installation.

12.Place the Briquet Rack in the grill bottom. See figure 10.

13.Spread the Briquets in a single layer evenly over the Briquet Rack. Do not overlap or stack briquet. There may be some briquets left over. Save them for future use. See figure 10.

14.Put cooking grids in place in the grill bottom. The cooking grids can be independently placed in different positions for different cooking heights above the Briquets. See figure 10.

15.Install Warming Rack as shown by figures 11, depending on your grill model.

16.If your grill is equipped with a side burner, the side burner has been factory-assembledand its gas hose has beenfactory-connectedto the grill. Mount the side burner on whichever side of the grill you choose and install two knobs on the side burner. See figure 12.

A.Determine which side of the grill the side burner is to be mounted on.

B.Install the side burner’s mounting bracket. The side burner mounting bracket installs exactly like a side shelf mounting bracket. See figure 7.

C.Lower the side burner onto the mounting bracket so that the side burner’s rear clamp is clamped around the back tube of the mounting bracket as shown by figure 12.

D.Attach the front clamp to side burner and the front tube of the mounting bracket with two No. 10-24x 3/8" screws, two 3/16” ID shakeproof washers, and two No.10-24nuts as shown by figure 12.

E.Push gas knob onto valve stem protruding through the side burner’s front panel as shown by figure 12. The knob will fit only one way on the stem. After knob is on the stem, turn the knob to the OFF position if not already there.

F.Attach lid knob to the side burner’s lid with one 1/4-20x 1/2" screw and one 1/2" OD shakeproof washer as shown by figure 12.

Figure 13 shows a side burner mounted on the left side of a grill. The side burner can be used to simmer, saute, boil or fry.

NOTE: PROPANE-gasgrills can only be equipped with PROPANE - gas side burners andNATURAL-gasgrills can only be equipped withNATURAL-gasside burners.

17.Connect gas supply to grill per A or B below. A. For PROPANE-gasgrills:

1. Place properly filled PROPANE-gascylinder in position and secure with the retainer provided.

2.Screw the grill’s regulator fitting onto the PROPANE - gas cylinder’s valve outlet male thread clockwise and tighten securely.

NOTE: Regulator’s female fitting has right hand threads. Check fittings on tank and regulator, they may be different or could be left hand threads. Vent on regulator must point down while the regulator is connected to the PROPANE - gas cylinder.

3.The gas supply must be turned OFF at the PROPANE - gas cylinder when the grill is not in use.

B.For NATURAL - gas grills:

1.Arrange with local gas company to have a gas supply line installed for the grill.

2.If the grill is mounted on an in-groundpost or patio base post, arrange with the local gas company to have the gas supply line connected to the grill.

3.If the grill is mounted on a cart, obtain Broilmaster’s NG12 twelve-footflexible hose andquick-disconnectkit to connect the grill to the gas supply line installed by the local gas company. Connect the flexible hose to the grill and gas supply line per the instructions furnished with the NG12 kit.

4.Always turn gas OFF at the gas supply line shutoff valve when a grill is not in use.

18.Check for gas leaks:

A.The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.5kPa).

B.The appliance 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 1/2 psi (3.5 kPa).

Check for gas leaks after connecting a PROPANE - gas cylinder to a grill, or when a cylinder has not been used for a long time, or when a grill (PROPANE or NATURAL model) is being used for the first time or has not been used for long time.

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FIGURE 10

COOKING GRID

INSTALLATION

FIGURE 12

SIDE BURNER ASSEMBLY

FIGURE 11

S5 WARMING RACK

INSTALLATION

FIGURE 13

SIDE BURNER

INSTALLED

FIGURE 14

LIGHTING INSTRUCTIONS

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