Char-Broil 4539937 User Manual

NATURAL GAS
CONVERSION KIT
Model # 4539937
FOR OUTDOOR USE ONLY
This Natural Gas Conversion Kit can be used ONLY with
Dual Fuel™ grills.
If you have questions or need assistance during assembly, please call 1-800-241-7548
WARNING
Read and follow all Safety Assembly,, and Use and Care Instructions in this Guide before assembling and cooking with this grill.
Failure to follow all instructions in this Use and Care Guide may lead to fire or explosion which could result in property, damage personal injury or death,.
Estimated assembly time: 45-60 minutes
The following are trademarks registered by W.C. Bradley Co. in the U.S. Patent and Trademark Office: Char-Broil®; America's Legendary Barbeque Company®; American Gourmet®; Bandera®; BrushHawg®; CB940®; Char-Diamonds®; Char-Broil Charcoal/Gas®; DiamondFlame®; Everybody Grills®; Everybody Outside®; FastStart®; Fireball®; Firenzy®; FlavorMaster®; Grill2Go®; Grill2Go® Express®; GrillLovers®; H20 Smoker®; Keepersof the Flame®;New Braunfels Smoker Company®;Oklahoma Joe's®; Patio Bistro®;Patio Caddie®; PatioKitchen®; Precision Flame®; Quantum®;Santa Fe®; Sear andGrill®; Sierra®; Signature Series®; The Big Easy®;The MinuteGrill®; Trentino®;Wild West Tradition®;and the following marks:
® ®
The following are trademarks of W.C. Bradley Co.: Commercial Series™; Designer Series™; Grill2Go® Advantage™; Longhorn™; Double Chef™; QuickSet™; Ready When You Are™; Hog and Yard Bird™; YouBring the Party™; SureFire™; Universal GrillParts™
TEC™ is atrademark ofTec Infrared Grills.
Protected underone ormore of thefollowing U.S. Patents:4,989,579; 5,421,319;5,458,309; 5,579,755; 5,996,573;6,114,666; 6,135,104;6,209,533; 6,279,566;6,331,108; 6,484,900; 6,526,876;6,595,197; 6,640,799; 6,640,803;6,729,873; 6,739,473; 6,749,424; 6,863,100; 6,935,327; 6,951,213; 6792,935; 7,047,590; D364,535; D372,637; D373,701; D377,735; D383,035; D397,910; D405,643; D406,005; D406,009 ; D413,043; D413,229; D414,982; D415,388; D416,164; D416,441; D417,587; D417,588; D422,516; D423,876; D428,303; D430,772; D435,396; D436,004; D438,059; D438,060; D438,427; D439,110; D442,505; D443,179; D443,354; D443,464; D447,384; D447,385; D447,909; D448,610; D448,614; D448,615; D448,616; D448,975; D449,492; D450,544; D451,759; D454,028; D454,031; D455,205; D455,206; D456,202; D456,222; D456,223; D457,789; D458,520; D458,760; D458,802; D459,088; D459,148 D459,149; D459,161; D459,163; D459,586; D459,943; D460,312; D460,313; D460,318; D461,359; D465,123; D465,693; D466,307; D466,439; D466,752; D473,414; D474,371; D477,498; D477,501; D477,504; D477,506; D477,746; D478,471; D478,472; D480,914; D491,410; D494,009; D494,413; D498,523; D500,359; D504,048;D530,098; D535,000; Canada: 87,743; 87,744;97,504; 99,355; 102,037; 104,200; 2,315,567;2,336,036; France: 010,231; 010,422; 010,590;010,849; 1,089,646; Germany: 1,089,646; SouthKorea: 384,565; China: 99,127,066.5; UnitedKingdom: 2,099,402;1,089,646. Other PatentsPending. © 2008W.C. BradleyCompany
Natural Gas Conversion Kit 4539937 • •11/04/083499893
TM REVISION 00
TABLE OF CONTENTS
USE AND CARE
For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Food Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Use and Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Parts List/ Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Main Burner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Natural Gas Hose Conversion. . . . . . . . . . . . . . . . . . . . . . .17-18
Sideburner Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-21
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Call Grill Service Center for Help and Parts
• To order non-warranty replacement parts or accessories please visit us on the web at or call
1-800-241-7548 and one of our friendly and knowledgeable agents will be glad to assist you.
Safety Symbols
The symbols and boxes shown below explain what each heading means. Read and follow all of the messages found throughout the manual.
www.charbroil.com
Natural Gas Connections and Service Regulators Above 1/2 psi.
Prior to 1998, all residual gas service regulators were set with an outlet pressure of 7 inches water column.
In the 1998 edition of NFPA 54, the National Fuel Gas Code, a change was made allowing service regulators of 2 and 5 psi.
With this change it was also required that an in line regulator be connected between the service regulator and the appliance regulator if the 2 or 5 psi system is used. This additional regulator is not supplied with the product.
It is possible for a consumer, making the connection themselves, or a plumber, not checking, to tap into a 2 or 5 psi line. If a pressure of 2 psi or greater is supplied to the appliance regulator on certain grills it will shut down and not deliver any gas to the grill. Other concerns are the quick disconnect socket and hose which are only rated to 1/2 psi.
If the quick disconnect socket, hose, and grill are properly connected and still not getting gas, delivery pressure needs to be verified. If pressure is greater than 1/2 psi, make sure that an in line regulator is present.
Once the grill has been over-pressured, the regulator may or may not have been damaged. The best practice is to replace the regulator.
WARNING
WARNING: Indicates an potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION: Indicates a potentially hazardous situation or unsafe practice which, if not avoided, may result in minor or moderate injury.
DANGER
DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
2
CAUTION:
Read and follow all safety statements, assembly instructions, and use and care directions before attempting to assemble and cook.
INSTALLER/ASSEMBLER:
Leave this manual with consumer.
CONSUMER:
Keep this manual for future reference.
WARNING:
Failure to follow all manufacturer’s instructions could result in serious personal injury and/or property damage.
CAUTION:
Some parts may contain sharp edges – especially as noted in the manual! Wear protective gloves if necessary.
WARNING
WARNING
CALIFORNIA PROPOSITION 65
1. Combustion by-products produced when using this product contain chemicals known to the State of California to cause cancer, birth defects, and other reproductive harm.
2. This product contains chemicals, including lead and lead compounds, known to the State of California to cause cancer, birth defects or other reproductive harm.
Wash your hands after handling this product.
Installation Safety Precautions
••Use grill, as purchased, only with LP (propane) gas and the
regulator/valve assembly supplied. A conversion kit must be purchased for use with natural gas. Grill installation must conform with local codes, or in their absence of local codes, with either the
Code, ANSI Z223.1/ 4, Natural Gas and Propane Installation Code, CSA B149.1, or Propane Storage and Handling Code, B149.2, or the Standard for Recreational Vehicles, ANSI A 119.2/NFPA 1192, and CSA Z240 RV Series, Recreational Vehicle Code, as applicable.
• All electrical accessories (such as rotisserie) must be electrically grounded in accordance with local codes, or
National Electrical Code, ANSI / NFPA 70 or Canadian Electrical Code, CSA C22.1.
fuel supply hoses away from any hot surfaces.
• This grill is safety certified for use in the United States and/or Canada only. Do not modify for use in any other location. Modification will result in a safety hazard.
NFPA 5
Keep any electrical cords and/or
National Fuel Gas
Do not attempt to repair or alter the hose/valve/regulator for any “assumed” defect. Any modification to this assembly will void your warranty and create the risk of a gas leak and fire. Use only authorized replacement parts supplied by manufacturer.
Food Safety
Food safety is a very important part of enjoying the outdoor cooking experience. To keep food safe from harmful bacteria, follow these four basic steps:
Wash hands, utensils, and surfaces with hot soapy water
Clean:
before and after handling raw meat and poultry.
Separate:
foods to avoid cross contamination. Use a clean platter and utensils when removing cooked foods.
Cook:
thermometer to ensure proper internal food temperatures.
Chill:
Seperate raw meats and poultry from ready-to-eat
Cook meat and poultry thoroughly to kill bacteria. Use a
Refrigerate prepared foods and leftovers promptly.
For more information call: USDA Meat and Poultry Hotline
at 1-800-535-4555 in Washington, DC (202) 720-3333, 10:00 am-4:00 pm .
How To Tell If Meat Is Grilled Thoroughly
Meat and poultry cooked on a grill often browns very fast on the outside. Use a meat thermometer to be sure food has reached a safe internal temperature, and cut into food to check for visual signs of doneness.
DANGER
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, keep away from the appliance and immediately call your gas supplier or your fire department.
CAUTION
For residential use only. Do not use for commercial cooking.
Whole poultry should reach 165 F. Juices should run clear and flesh should not be pink.
o
Hamburgers made of any ground meat or poultry should reach 160 F, and be brown in the middle with no pink juices. Beef, veal and lamb steaks, roast and chops can be cooked to 145 F. All cuts of pork should reach 160 F.
NEVER partially grill meat or poultry and finish cooking later. Cook food completely to destroy harmful bacteria. When reheating takeout foods or fully cooked meats like hot dogs, grill to 165 F, or until steaming hot.
WARNING:
to the minimum internal temperatures listed in the table on next page.
o
To ensure that it is safe to eat, food must be cooked
o
o
o
3
USDA Safe Minimum Internal Temperatures*
Fish Pork Egg Dishes Steaks and Roasts of Beef,
Veal or Lamb Ground Beef, Veal or Lamb Whole Poultry (Turkey,
Chicken, Duck, etc.) Ground or Pieces Poultry
(Chicken Breast, etc.)
*United States Department of Agriculture
CAUTION
Using pots larger than 6 quarts in capacity could exceed weight limit of the side burner shelf, resulting in failure of grill cart components.
145 F° 160 F° 160 F°
145 F° 160 F°
165 F° 165 F°
USE AND CARE
DANGER
NEVER store a spare cylinder under or near the applience or in an enclosed area.
Never fill a cylinder beyond 80% full.
WARNING
1. Do not store or use gasoline or other flammable liquids or vapors 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.
An over filled or improperly stored cylinder is a hazard due to possible gas release from the safety relief valve.
f you see, smell or hear gas escaping, immediately get away from the LP cylinder/appliance and call your fire department.
This could cause an intense fire with risk of property damage, seriouse injury or death.
LP Cylinder Removal, Transport and Storage
1.
Turn OFF all control knobs and LP cylinder valve. Turn coupling nut counterclockwise by hand only - do not use tools to disconnect. Loosen cylinder screw beneath bottom shelf, then lift LP cylinder up and out of cart. Install safety cap onto LP cylinder valve. Always use cap and strap supplied with valve.
safety cap as directed may result in serious personal injury and/or property damage.
2.
A disconnected LP cylinder in storage or being transported must have a safety cap installed (as shown). Do not store an LP cylinder in enclosed spaces such as a carport, garage, porch, covered patio or other building. Never leave an LP cylinder inside a vehicle which may become overheated by the sun.
Failure to use
Do not store an LP cylinder in an area where children play.
3.
4
LP Cylinder
The LP cylinder used with your grill must meet the following requirements:
1. Use LP cylinders only with these required measurements: 12” (30.5cm) (diameter) x 18” (45.7cm) (tall) with 20 lb. (9kg) capacity maximum.
2. LP cylinders must be constructed and marked in accordance with specifications for LP cylinders of thr U.S. Department of Transportation (DOT) or for Canada, CAN/CSA-B339, cylinders, spheres and tubes for transportation of dangerous goods. Transport Canada (TC). See cylinder collar for marking.
3.
LP cylinder valve must have:
-Type 1 outlet compatable with
regulator or grill.
-Safety relief valve.
-UL listed Overfill Protection
Device (OPD). This OPD safety feature is identified by a unique triangular hand wheel. Use only LP cylinders equipped with this type of valve.
4. LP cylinder must be arranged for vapor withdrawal and include collar to protect LP cylinder valve. Always keep LP cylinder in upright position during use, transit or storage.
OPD Hand Wheel
LP Cylinder Exchange
Many retailers that sell grills offer you the option of replacing your empty LP cylinder through an exchange service. Use only those reputable exchange companies that inspect, precision fill, test and certify their cylinders.
for an OPD safety feature-equipped cylinder as described in the “LP Cylinder” section of this manual.
Always keep new and exchanged LP cylinders in upright position during use, transit or storage.
Leak test new and exchanged LP cylinders BEFORE connecting to grill.
Exchange your cylinder only
LP Cylinder Leak Test
For your safety
Leak test must be repeated each time LP cylinder is exchanged or refilled.
Do not smoke during leak test.
Do not use an open flame to check for gas leaks.
Grill must be leak tested outdoors in a well-ventilated area, away from ignition sources such as gas fired or electrical appliances. During leak test, keep grill away from open flames or sparks.
Use a clean paintbrush and a 50/50 mild soap and water solution. Brush soapy solution onto areas indicated by arrows in figure below.
LP cylinder in upright position for vapor withdrawal
LP (liquefied Petroleum Gas)
LP gas is nontoxic, odorless and colorless when produced.
Your Safety
cabbage) so that it can be smelled. LP gas is highly flammable and may ignite unexpectedly when
mixed with air.
, LP gas has been given an odor (similar to rotten
LP Cylinder Filling
Use only licensed and experienced dealers. LP dealer before filling. Dealer should NEVER fill LP cylinder more than 80% of LP
cylinder volume. Volume of propane in cylinder will vary by temperature.
A frosty regulator indicates gas overfill. Immediately close LP cylinder valve and call local LP gas dealer for assistance.
Do not release liquid propane (LP) gas into the atmosphere. This is a hazardous practice.
To remove gas from LP cylinder, contact an LP dealer or call a local fire department for assistance. Check the telephone directory under “Gas Companies” for nearest certified LP dealers.
must purge new cylinder
For
Do not use household cleaning agents.
components can result.
Damage to gas train
WARNING
If “growing” bubbles appear do not use or move the LP cylinder. Contact an LP gas supplier or your fire department!
5
Connecting Regulator to the LP Cylinder
1. LP cylinder must be properly secured onto grill. (Refer to assembly section of your grill manual).
2. Turn all control knobs to the OFF position.
3. Turn LP cylinder OFF by turning hand wheel clockwise to a
Full Stop.
4. Remove the protective cap from LP cylinder valve. Always use cap and strap supplied with valve.
c
k
w
o
i
l
C
f
f
O
s
e
Straight
Hold coupling nut and regulator as shown for proper connection to LP cylinder valve.
Safety Relief Valve
Strap and Cap
Do not use a POL transport plug (plastic part with external threads)! It will defeat the safety feature of the valve.
5. Hold regulator and insert nipple into LP cylinder valve. Hand-tighten the coupling nut, holding regulator in a straight line with LP cylinder valve so as not to cross-thread the connection.
Nipple has to be centered into the LP cylinder valve.
OPD Hand Wheel
Type 1 outlet with thread on outside
Connecting Regulator to the LP Cylinder (Con’t.)
6. Turn the coupling nut clockwise and tighten to a . The regulator will seal on the back-check feature in the LP cylinder valve, resulting in some resistance.
one-half to three-quarters turn is required to complete the connection. Tighten by hand only - do not use tools.
NOTE:
If you cannot complete the connection, disconnect regulator and repeat steps 5 and 6. If you are still unable to complete the connection,
do not use this regulator!
Full Stop
An additional
DANGER
Do not insert any tool or foreign object into the valve outlet
or safety relief valve. You may damage the valve and cause a leak. Leaking propane may result in explosion, fire, severe personal injury, or death.
WARNING
Outdoor gas appliance is not intended to be installed in or on a boat. Outdoor gas appliance is not intended to be installed in or on an RV. Never attempt to attach this grill to the self-contained LP gas system of a camper trailer or motor home. Do not use grill until leak-tested. If a leak is detected at any time, and call the fire department. If you cannot stop a gas leak close LP cylinder valve and call LP gas supplier or your fire department!
STOP
IMMEDIATELY
6
Leak Testing Valves, Hoses and Regulator
1.
Turn all control knobs to the OFF position.
2. Be sure regulator is tightly connected to LP cylinder.
3. Completely open LP cylinder valve by turning hand wheel counterclockwise. If you hear a , turn gas off immediately. There is a major leak at the connection.
before proceeding.
4. Brush soapy solution onto areas circled below.
Never remove threaded orifice at end of valve during leak testing of valves.
rushing sound
Correct
WARNING
For Safe Use of Your Grill and to Avoid Serious Injury:
-Do not let children operate or play near grill.
-Keep grill area clear and free from materials that burn.
-Do not block holes in sides or back of grill.
-Check burner flames regularly.
-Use grill only in well-ventilated space. use in enclosed space such as carport, garage, porch, covered patio, or under an overhead structure of ant kind.
-Do not use charcoal or ceramic briquets in a gas grill. (Unless briquets are supplied with your grill)
-Use grill at least 3 ft. from any wall or surface.
Maintain 10ft. clearance to objects that can catch fir or sources of ignition such as pilot lights on water heaters, live electrical appliances, etc.
NEVER
5. If “growing” bubbles appear there is a leak. Close LP cylinder valve immediately and retighten connections. If leaks cannot be stopped do not try to repair. Call for replacement parts. Order new parts by giving the serial, model number and name and part number of items needed (see parts list) to the Grill Service Center at 1-888-430-7870.
6. Always close LP cylinder valve after performing leak test by turning hand wheel clockwise.
Apartment Dwellers:
Check with apartment management to learn the requirements and fire codes for using an LP gas grill in your apartment complex. If allowed, use outside on the ground floor with a three (3) foot clearance from walls or rails. Do not use on or under balconies.
NEVER attempt to light burner with lid closed. A buildup of non-ignited gas inside a closed grill is hazardous.
Never operate grill with LP cylinder out of correct position specified in assembly instructions.
Always close LP cylinder valve and remove coupling nut before moving LP cylinder from specified operation position.
7
Safety Tips
- Before opening LP cylinder valve, check the coupling nut for tightness.
- When grill is not in use, turn off all control knobs and LP cylinder valve.
Never move grill while in operation or still hot.
-
- Use long-handled barbecue utensils and oven mitts to avoid
burns and splatters.
- Maximum load for sideburner and side shelf is 10 lbs.
- The grease tray be inserted into grill and emptied after each use. Do not remove grease tray until grill has completely cooled.
- Clean grill often, preferably after each cookout. If a bristle brush is used to clean any of the grill cooking surfaces, ensure no loose bristles remain on cooking surfaces prior to grilling. It is not recommended to clean surfaces while grill is hot.
- If you notice grease or other hot material dripping from grill onto valve, hose or regulator, turn off gas supply at once. Determine the cause, correct it, then clean and inspect valve, hose and regulator before continuing. Perform a leak test.
- Keep ventilation openings in cylinder enclosure (grill Cart) free and clean of debris.
- Do not store objects or materials inside the grill cart enclosure that could block the flow of combustion air to the underside of either the control panel or the firebox bowl.
- The regulator may make a humming or whistling noise during operation. This will not affect safety or use of grill.
- If you have a grill problem see the of your grill manual.
- If the regulator frosts, turn off grill and LP cylinder valve immediately. This indicates a problem with the cylinder and it should not be used on any product. Return to supplier!
must
“Troubleshooting Section”
CAUTION
Ignitor Lighting Do not lean over grill while lighting. Light burners one at a time.
1. Turn all Gas Burner Control Valves.
2. Turn gas source or tank.
3. Open lid during lighting.
4. To ignite turn burner control valve to .
5. Push and hold button until the burner
6. If ignition does not occur in 5 seconds, turn the burner controls
7. Ignite remaining burners by repeating steps 4 through 6 for each
If ignition still does not occur, follow match-lighting instructions.
lights.
OFF
burner.
OFF ON
ELECTRONIC IGNITOR
, wait 5 minutes, and repeat the lighting procedure.
Main Burner Match-Lighting Do not lean over grill while lighting.
1. Turn all Gas Burner Control Valves.
2. Open lid during lighting. Turn gas source or tank.
3. Place match into match holder (hanging from side of cart). Light
4. Push in and turn control knob to high position for the desired
5. If ignition does not occur in 5 seconds, turn the burner controls
6. Ignite remaining burners by repeating steps 3 through 5 for each
OFF
ON
match, place into lighting hole for desired burner to light. The lighting holes are located at the front of the cooking grates between the emitter plate mounting brackets.
burner to light. Be sure burner lights and stays lit.
OFF
burner.
, wait 5 minutes, and repeat the lighting procedure.
Putting out grease fires by closing the lid is not possible. Grills are well ventilated for safety reasons.
Do not use water on a grease fire. Personal injury may result. If grease fire develops, turn knobs and LP cylinder off.
Do not leave grill unattended while preheating or burning off food residue on Hi. If grill has not been regularly cleaned, a grease fire can occur that may damage the product.
WARNING
Turn controls and gas source or tank OFF when not in use.
CAUTION
If ignition does NOT occur in 5 seconds, turn the burner controls OFF, wait 5 minutes and repeat the lighting procedure. If the burner does not ignite with the valve open, gas will continue to flow out of the burner and could accidently ignite with risk of injury.
8
Emitter Plate Brackets
Side Burner Match-Lighting Do not lean over grill while lighting.
1. Open lid during lighting. Turn gas source or tank.
2. Place lit match near burner.
3. Turn sideburner knob to high position.
Be sure burner lights and stays lit.
4. If ignition does not occur in 5 seconds,
turn the burner controls , wait 5 minutes, and repeat the lighting procedure.
ON
OFF
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