Thermador CGB30RCULP, CGB36RU, CGB48RU, CGB48RSBU Installation Instructions

Installation Instructions

for

Thermador Char Glo

Outdoor Barbecues

Models:

CGB30RCULP • CGB36RU

CGB48RU • CGB48RSBU

®

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Installer: Please leave these instructions with the unit for the owner.

Owner: Please retain these instructions for future reference.

WARNING: If the information in this manual is not followed exactly, a fire or

explosion may result causing property damage, personal injury or death.

AVERTISSEMENT: Si l’information dans ce manuel n’est pas suivie
exactement, une incendie ou une explosion peut résulter, entrainant des
dégats matériels, des blessures ou la mort.

Inside Front Cover

Contents

SECTION 1: Safety Information ................................................................. 2

SECTION 2: Gas Requirements................................................................... 3

Natural Gas Requirements......................................................... 3

Propane Gas Requirements........................................................3

Gas Consumption ........................................................................ 3

Propane Hook-up .........................................................................3

SECTION 3:

Built-In Installations ....................................................................................... 5

Cabinet Preparation ...................................................................................... 5

Site Preparation...................................................................... 5

SECTION 4: Electrical Cautions .................................................................. 7

Electrical Requirements................................................................................ 7

Grounding Instructions................................................................................. 7

SECTION 5: Unpacking, Moving and Placing the Unit ....................8 - 10

Locating your Char Glo® Barbecue ........................................................... 8

Liquid Propane to Natural Gas Conversion .......................................... 10

Gas and Electrical Hook-up ....................................................................... 11

Side Panel Installation .................................................................................. 11

SECTION 6: Test and Adjustment.............................................................. 12

Checking for Leaks ...................................................................................... 12

Burner Air Adjustment ................................................................................ 12

Installer Checklist......................................................................................... 12

Installation...................................................................................................... 12

Gas Supply ..................................................................................................... 12

Electrical ......................................................................................................... 12

Page 1

SECTION 1: SAFETY INFORMATION

FOR YOUR SAFETY

If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Open lid.

4. If odor continues, immediately call your gas
supplier or your fire department.

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.

AVERTISSEMENT

S’il y a une odeur de gaz:

1. Coupez l’admission de gaz de l’appariel.

2. Ènteindre toute flamme nue.

3. Ouvrir le couvercle.

4. Si l’odeur peraiste, appeler immediatement
votre compagnie de gaz ou votre departement
des incendies.

AVERTISSEMENT

1. Ne pas entreposer ni utiliser de l‘essence ni
d’autres vapeurs ou liquides inflammables dans
le voisinage de l’appareil, ni de tout autre
appareil.

2. Une bouteille de propane qui n’est pas
raccordée en vue de son utilisation, ne doit
pas etre entreposée dans le voisinage de cet
appareil ou de tout autre appareil.

Installation and service must be performed by a qualified installer,

service agency or the gas supplier.

TESTED IN ACCORDANCE WITH ANSI Z21.58 – 1995, ANSI Z21.58a – 1998
STANDARD FOR OUTDOOR COOKING GAS APPLIANCES, AND CAN/CGA 1.6-M95,
CAN/CGA 1.6a-M98 STANDARD FOR OUTDOOR COOKING GAS APPLIANCES.

This unit is for outdoor use only in a well-ventilated area. Not to be
used in a building, garage or any other enclosed area.

Check your local building codes for the proper method of installation. In the absence of local codes this
unit should be installed in accordance with the National Fuel Gas Code No. Z223.1 Current Issue and
National Electrical Code ANSI/NFPA No. 70 Current Issue or the CAN/CGA – B149.1 Natural Gas
Installation Code or CAN/CGA - B149.2 Propane Installation Code and C22.1 Canadian Electrical Code
Part1.

Page 2

SECTION 2: GAS REQUIREMENTS

NATURAL GAS REQUIREMENTS -

Inlet Connection: 1/2" NP with 3/8" NPT reducer adapter.

Supply Pressure: 6" to 14" W.C.

Manifold Pressure: 5" W.C.

PROPANE GAS REQUIREMENTS -

Inlet Connection: 1/2" NP with 3/8" NPT reducer adapter.

Supply Pressure: 11" to 14" W.C.

Manifold Pressure: 10" W.C.

IMPORTANT: A manual gas shut off valve must be installed external to the appliance, in

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PROPANE HOOK-UP

a location accessible with the unit installed in the enclosure. Make sure the valve is turned
off prior to connecting the appliance.

IMPORTANT: Un robinet manuel d'isolement doit étre installé à l’extérieur de l’appareil, dans
un emplacement accessible avec l’unité installée dans la module. Assurez-vous que le robinet est
fermé avant de brancher l’appareil.

Tank Gas Regulator

Gas Regulator

Gas Hose

LP Gas Tank

GAS CONSUMPTION

The total gas consumption of the Thermador® Char Glo® barbecues with all burners on "HI" is as
follows:

CGB30RCULP = 52,000 BTU/Hr

CGB36RU = 77,000 BTU/Hr
CGB48RU = 109,000 BTU/Hr

CGB48RSBU = 107,000 BTU/H

Page 3

SECTION 2: GAS REQUIREMENTS

For Massachusetts Installations:

1. Shut-off valve must be a “T” handle gas cock.

2. Flexible gas connector must not be longer than 36 inches.

3. Not approved for installation in a bedroom or a bathroom unless unit is direct vent.

CAUTION: The appliance must be isolated from the gas supply system by closing its

individual manual shut-off valve during any pressure testing of the gas supply
piping system at test pressures equal to or less than 1/2" psig (3.5kPa).

When checking the manifold gas pressure, the inlet pressure to the appliance
regulator should be at least 6.0" W.C. for natural gas, and 11.0" W.C. for
propane.

Do not attempt any adjustment of the pressure regulator.

ATTENTION: L’appareil doit étre isolé du circuit d’alimentation de gaz en fermant son

rob1net manuel d’isolement individuel pendant toutes essais sous pression
du circuit de tuyauterie d’alimentation de gaz aux pressions d’essai égales à
ou moins de 3.5kPa (1/2 psig).

En controlant la pression de gaz du tubulure, la pression de prise au
régulateur de l’appareil devrait étre au moins 11.2mm HG pour gaz naturel,
et 20.5mm HG pour gaz de propane.

N’essayez aucun réglage du régulateur de pression.

CAUTION: When connecting to propane gas supply, make certain that the propane gas

tank is equipped with its own high pressure regulator in addition to the
pressure regulator supplied with the appliance. The pressure of the gas at the
appliance regulator must not exceed 14" water column.

ATTENTION: En se reliant a l approvisionnement de gaz de propane, assurez-vous que le

réservoir de gaz de propane est équipé de son Propre régulateur à haute
pression en peus du régulateur de Pression fourni avec l’appareil. La pression
du gaz au régulateur de l’appareil ne doit pas exéceder 26.1 mm HG.

Page 4

SECTION 3: SITE PREPARATION

BUILT-IN INSTALLATIONS

Determine a suitable location for the barbecue by
taking into account exposure to wind and availability of
gas and electrical supplies. Insure that the gas supply line
and electrical supply are located in close proximity to
the unit to keep connections to the unit as short as
possible and allow for installation and removal of the
unit from the enclosure. Allow adequate area around
the unit for dissipation of smoke produced during
cooking.

CLEARANCES (Refer to Figures 1 and 2)

3" minimum for

hood clearance to

back wall

CABINET PREPARATION

The model CGB36RU, CGB48RU and CGB48RSBU
barbecues are designed to be built into a masonry
enclosure. Refer to Figures 1 and 2 for cutout dimen­sions and location of utilities. Note that the floor of the
enclosure area must be smooth and free of obstruc­tions to allow the unit to be rolled into position in the
cutout.

FIGURE 1
Cutout Dimensions

36" or 48" Unit in
Built-In Island

FIGURE 2

CharGlo® Outdoor Barbecues Overall Width

Model No. Overall Dimensions Cutout Dimensions (Shelves Up)

ABC D EF G

5

CGB30RCULP 50­CGB36RU 50­CGB48RSBU 50­CGB48RU 50-

/8 30 26-5/8 N/A N/A N/A 67

5

/8 36 26-5/8 37-3/8 35-5/16 22-3/4 73

5

/8 48 26-5/8 37-3/8 47-5/16 22-3/4 85

5

/8 48 26-5/8 37-3/8 47-5/16 22-3/4 85

Note: All height width and depth dimensions are shown in inches.

All Char-Glo

®

Outdoor Barbecues

are CGA and AGA approved.

Page 5

SECTION 3: SITE PREPARATION

To combustible construction -

Below the cooking surface, combustible construction
can be placed adjacent to the unit. Clearance of 3" at the
lower left rear of the unit must be maintained to allow
adequate routing of the gas and electrical supply lines.

Minimum horizontal clearance from sides and back of
unit to adjacent vertical combustible construction ex­tending above top of unit, 12" from sides and 20" from
back.

Degagement horizontal minimal a respecter entre les
cotes et l’arriere de l’appareil et une construction
combustible verticale adjacent depassant la partie
superieure de l’appareil, soit 12" (305mm) pounces des
cotes et 20" (508mm) ponces de l’arriere.

To non-combustible construction -

Above the cooking surface, a minimum 8" clearance
from the sides is required to allow use of the rotisserie
motor and skewer. A minimum of 3" clearance from the
rear is required to allow proper opening of the hood.

Below the cooking surface, non-combustible construc­tion can be placed directly adjacent to the unit. Clear­ance of 3" at the lower left rear of the unit must be
maintained to allow adequate routing of the gas and
electrical supply lines.

In all installations, do not locate this outdoor cooking
gas appliance under unprotected combustible over­head construction.

II est interdit d’installer le present appareil au-dessous
des surfaces combustibles non protegees.

Page 6

SECTION 4: ELECTRICAL REQUIREMENTS

AND GROUNDING INSTRUCTIONS

CAUTION CAUTION

Installation of electrical supply circuit should be done by a qualified electrician in accordance with local
codes and ordinances. In the absence of local codes or ordinances, the supply should be installed in
accordance with the National Electric Code ANSI/NFPA No. 70, current issue, or Canadian Electric Code
C22.1 Part 1.

The Thermador® Char Glo® barbecues use an electronic ignition system that requires a 120 VAC, 15A,
60 Hz power supply. A properly grounded duplex outlet must be provided adjacent to the lower left rear
corner of the unit. See Figures 2 (Page 5) and 2A (below).

A properly grounded duplex outlet made for outdoor applications should also be provided above the level
of the cooking surface on the left side of the unit. This outlet is required for connection of the rotisserie
motor. See Figure 2 (Page 5).

WARNING

Electrical Grounding Instructions

This outdoor cooking gas appliance is
equipped with a three-prong (grounding)
plug for your protection against shock haz­ard and should be plugged directly into a
properly grounded three-prong receptacle.
Do not cut or remove the grounding prong
from this plug.

AVERTISSEMENT

Instruction pour la mise

a la terre electrique

Cet appareil est muni d’une fiche a trots
broches (mise a la terre) afin de vous proteger
des chocs et doit etre branche dire~ement
dans une prise de courant a trots broches
adequatement mise a la tem. II ne faut pas
couper ou enlever la broche de mise a la tem
de cette fiche.

Figure 2A

BARBECUE

Three-Prong Plug and Receptacle

Page 7

SECTION 5: UNPACKING, MOVING AND PLACING THE UNIT

LOCATING YOUR CHAR GLO® BARBECUE

Leaving the unit on the pallet, move the unit close to the final installation site. Unpack and remove all accessory items, packing
materials and product literature from inside the unit. Verify the gas supply type. If the unit is not compatible with the gas supply,
it will be necessary to convert it for use with the supply. See conversion instructions below.

CONVERSION KIT BY MODEL

Model No. Orifice Description Part Number Quantity Remarks

CGB30RCULP #46 Orifice Hood, Grill Burner 08-04-082-04 2 To Convert LP To NG

#53 Orifice Hood, Infrared Burner 08-04-082-01 1
Conversion Sticker 08-04-731 1

CGB36RU #54 Orifice Hood, Grill Burner 08-04-082-05 3 To Convert NG To LP

#59 Orifice Hood, Infrared Burner 08-04-082-02 1
#73 Orifice, Smoker Burner 08-04-066-04 1
Conversion Sticker 20-09-337 1

CGB48RSBU #54 Orifice Hood, Grill Burner 08-04-082-05 3 To Convert NG To LP

#59 Orifice Hood, Infrared Burner 08-04-082-02 1
#73 Orifice, Smoker Burner 08-04-066-04 1
#56 Orifice, Side Burner 15-10-186 2
Conversion Sticker 20-09-337 1

CGB48RU #54 0rifice Hood, Grill Burner 08-04-082-05 4 To Convert NG To LP

#59 Orifice Hood, Infrared Burner 08-04-082-02 2
#73 Orifice, Smoker Burner 08-04-066-04 1
Conversion Sticker 20-09-337 1

Tools/Parts Required

Socket Driver-1/4" Drive, 3" minimum extension
3/16" Or 7 mm Socket or Wrench
1/2" Deep Well Socket
1/2" Open Wrench

Natural Gas to Liquid Propane Conversion

Models CGB36RU, CGB48RU and CGB48RSBU are
manufactured at the factory for use with natural gas, and as
such require conversion for use with an LP gas supply. The
conversion should be done by a qualified technician or your
gas supplier. All orifices required for conversion are provided
with the units. The following steps are necessary to convert
for LP operation -

1. Make sure that the unit is disconnected from the gas and
electrical supplies.

2. Remove the grill grates and radiants. Unbolt the main
burners from their attachment at the rear of the burner
box and remove.

3. Remove the knobs and control panel from the unit.

4. Locate the main burner orifices. From inside control
panel area, locate the brass elbows that the orifices are
attached to. Use a wrench on the flats of these elbows
to keep them from turning during orifice removal and
installation. Remove the main burner orifices and replace
with the LP orifices supplied (marked 54). Do not over­tighten orifices. Orifice must extend a minimum of 1/8"
into main burner air shutter with burner installed. Make
sure burner will not disengage from orifice..

Phillip Screwdriver
Slotted Screwdriver
Masking Tape

5. From behind the unit, remove the louvered cover on the
infrared rotis burner housing.

6. Locate the infrared burner orifice and remove. Replace
with the LP orifice supplied (marked 59).

7. Locate the smoker burner. Slide the orifice out of the
burner and remove. Replace with the LP orifice supplied
(marked 73). Reinstall the orifice into the burner.

8. On Model CGB48RSBU, convert the side burners for LP
operation as follows:

A. Remove the grate, burner caps, venturis and burner

bases. See Fig. 3, next page.

B. Remove the burner orifices. Use a 7mm hex socket

on a 3" ratchet extension and apply a piece of tape
to the socket to hold the orifice in the socket while
removing. See Fig. 3A, next page.

C. Replace with the LP orifices supplied (number 115).

Tighten until snug. See Fig 3B, next page.

D. Reassemble the burner bases and venturis. Reinstall

burner caps and grate.

NOTE: Install the conversion sticker (supplied)

beside the rating label.

Page 8

SECTION 5: UNPACKING, MOVING AND PLACING THE UNIT

TAPE

9. On all models, the bypass jet must be turned clockwise with a small flat-bladed screwdriver until fully
seated to set proper low flow rate. See Figures 4 and 5.

10. Models CGB36RU, CGB48RU and

CGB48RSBU are equipped with a pressure
regulator that is permanently mounted within
the cart. The regulator is set for natural gas.
For use with propane, it must be converted.
The regulator is located in the left storage

compartment. Using a flat blade screwdriver,
remove the cap on the top of the regulator
and turn the cap over so that the letters LP are
exposed. Make sure the spring in the regulator
remains in position. Reattach the cap to the
regulator. See Figures 6 and 6A, below.

Page 9

SECTION 5: UNPACKING, MOVING AND PLACING THE UNIT

11. If models CGB36RU, CGB48RU or CGB48RSBU
will be used with an LP cylinder, follow these steps:

A. Disconnect the existing flexible gas hose from

the regulator and remove hose.

B. The proper LP hose and regulator assembly

must be provided. Accessory Model LPHose is
available at your Thermador dealer. (Note:
The permanently mounted regulator on the
end of the manifold will still be used, but must
be converted for LP operation per Step 10 on
Page 9). This assembly can be purchased locally
provided it meets the following specifications:

Hose length to be 24".
Regulator must be a high pressure, high volume

unit capable of supplying adequate gas flow
based on the input rating of the unit (refer to
Gas Consumption in Section 2).

The inlet connector on the LP regulator must
be compatible with the LP cylinder valve.

The hose and regulator assembly must be AGA
certified for use with LP gas in an outdoor
application.

C. Connect the LP hose to the regulator. Use a

pipe sealant approved for use with LP gases on
all threads.

D. Attach gas regulator label (included with LP

orifices) to rear wall of cart, adjacent to
regulator.

12. Connect the unit to the gas supply (supply hose to
house supply, or LP regulator to tank valve).

13. Turn on the gas supply but do not attempt to light
any burner. Check the unit for leaks per the
instructions in Section 6 (Page 12).

14. Reinstall control panel and knobs. Reinstall the rear
cover on the infrared burner housing. Reinstall
main burners, making sure to install and tighten the
nuts that retain the burners at the rear of the
burner box. Connect the unit to the electrical
supply. Light all burners one by one and verify
proper operation on high and low control settings.
See Section 6 (Page 12).

15. Reinstall radiants and grill grates.

LIQUID PROPANE TO NATURAL GAS CONVERSION

Model CGB30RCULP is manufactured at the factory
for use with propane, and as such requires conversion
for use with a natural gas supply. The conversion
should be done by a qualified technician or your gas
supplier. All orifices required for conversion are
provided with the unit. The following steps are
necessary to convert for Natural Gas operation -

1. Make sure that the unit is disconnected from
the gas and electrical supplies.

2. Remove the grill grates and radiants. Unbolt the
main burners from their attachment at the rear
of the burner box and remove.

3. Locate the main burner orifices. Remove the
main burner orifices and replace with the Natural
Gas orifices supplied (marked 46). Do not over­tighten orifices. Orifice must extend a minimum
of 1/8" into main burner air shutter with burner
installed. Make sure burner will not disengage
from orifice.

4. From behind the unit, remove the louvered

cover on the infrared rotisserie burner housing.

5. Locate the infrared burner orifice and remove.
Replace with the Natural Gas orifices supplied
(marked 53).

6. Remove the knobs and control panel from the
unit.

7. The bypass jet must be turned counterclockwise
one to one and one-half turns to set proper low
flow rate. See Figures 4 and 5, Page 9.

8. Model CGB30RCULP will require the addition
of a pressure regulator set for 5" W.C. for use
with natural gas. It will be attached to the end
of the manifold, located in the left storage
compartment. See Figure 6.

This regulator can be purchased locally provided
it meets the following specifications:

• The regulator must be rated for 5" W.C.

with capacity capable of supplying adequate

Page 10

gas flow based on the input rating of the unit
(refer to Gas Consumption in Section 2).

certified for use with natural gas in an outdoor
application. Connect the hose to the regulator.

• The regulator must be AGA certified for
use with natural gas in an outdoor
application.

9. Remove the LP hose and regulator assembly.
Remove the coupling from the end of the
manifold.

10. Connect the pressure regulator to the end of
the manifold. Insure that the arrow on the
regulator body points in the direction of flow ­toward the unit.

11. A flexible gas hose must be provided. This hose
can be purchased locally provided it is AGA

GAS AND ELECTRICAL HOOK-UP

With the unit in front of the enclosure, connect the
gas supply hose to the manual shut-off valve and
open valve. Check the connection points at the
shut-off valve for any leaks and repair prior to
installation of the unit. Connect the power supply
cord to the electrical supply outlet.

Roll the unit into position in the enclosure. Make

12. Connect the unit to the gas supply.

13. Turn on the gas supply but do not attempt to
light any burners. Check the unit for leaks per
the instructions in Section 6, Page 12.

14. Reinstall main burners, making sure to install
and tighten the nuts that retain the burners at
the rear of the burner box. Reinstall the cover
on the infrared burner housing. Connect the
unit to the electrical supply. Light all burners
one by one and verify proper operation. See
Section 6, Page 12.

15. Reinstall radiants and grill grates.

sure that the caster wheels do not roll over the gas
supply line or power supply cord as the unit is
installed in the enclosure. Lock the caster brakes to
keep the unit in position.

Install the kick panel by screwing it into place at the
bottom of the unit. See Figure 7.

SIDE PANEL INSTALLATION

If the unit will be freestanding, accessory panel kits
are available. Install the side panels, side shelves and
rear panel per the instructions provided in the kit.

Gas and electrical hookups are the same as above.
Lock the caster brakes when not moving the unit.

Page 11

SECTION 6: TEST AND ADJUSTMENT

CHECKING FOR LEAKS

All points of connection to the gas supply should be
checked for leaks at time of installation or anytime
you smell gas. It is also advisable to recheck them
periodically. Follow the steps outlined below:

A. Make a soap solution of one part liquid detergent

and one part water.

B. Make sure all controls are in the "OFF" position.

Turn on the gas supply to the unit. Use a spray
bottle, brush or rag to apply the solution to all
fittings and points of connection from the supply
stub out up to and including the inlet to the

BURNER AIR ADJUSTMENT

All burners are adjusted for proper flame
characteristics at time of assembly. If the unit has
been converted for use with alternate gas supply,
some adjustment of the air shutter on the main
burner may be necessary. Refer to Figure 8. If
adjustment is required, loosen the screw on the air
shutter and close or open shutter as required to
achieve proper flame characteristics. Tighten the
screw after adjustment.

manifold. Bubbles will form where a leak exists.

C. If a leak is present, shut off the gas at the supply.

Tighten any leaking fittings, turn on the gas and
recheck.

D. If the unit has been converted for use with an

alternate gas, make sure the technician checks
for leaks at all points of connection in the control
panel area and at the infrared burner prior to
reassembly of the control panel and cover (Refer
to NG to LP Conversion, LP to NG Conversion
instructions in Section 5).

All burners should exhibit flames which are blue and
stable, with no yellow-tipping, lifting or excessive
noise when operating on either natural or LP gases.
See Figure 8 for pictorial representation of proper
flame characteristics.

The infrared rotis burner, smoker burner and surface
burners on model CGB48RSBU are not adjustable.

✓ INSTALLER CHECKLIST ✓

INSTALLATION

— Placement of unit.
— Specified clearances maintained to combustible or

noncombustible surfaces as applicable.

GAS SUPPLY

— Appliance is connected to the proper type of gas

supply.

— Manual gas shut off valve is installed in an accessible

location (with unit installed in enclosure for built-

in installations).
— Unit tested and free from gas leaks.
— Gas supply pressure does not exceed 14" W.C.

FIGURE 8

If any of the flame characteristics noted above are
observed, check the burner for dirt or residue in
the ports, spider webs, etc., and clean or repair as
necessary.

ELECTRICAL

— Properly grounded receptacle is present for unit

and rotisserie motor as necessary.

— The burner box area is free of any packing materials

and that the burners, radiants and grates are
properly located and installed.

— Burner caps properly positioned and seated on

burner bases (Model CGB48RSBU only).

— If the unit is to be used with propane gas, verify that

the LP gas supply has its own high pressure
regulator in addition to the pressure regulator
supplied with the appliance.

Page 12

Inside Back Cover

Specifications are for planning purposes only. Refer to installation instructions and consult your countertop supplier prior to
making counter opening. Consult with a heating and ventilating engineer for your specific ventilation requirements. For the
most detailed information, refer to installation instructions accompanying product or write Thermador indicating the model
number.

Thermador reserves the right to change specifications or design without notice. Some models are certified for use in Canada.
Thermador is not responsible for products which are transported from the United States for use in Canada. Check with your

local Canadian distributor or dealer. Thermador, 5551 McFadden Avenue, Huntington Beach, CA 92649.

For the most up to date critical installation dimensions by fax, use your fax handset
and call 702/833-3600. Use code #8030.

5551 McFadden Avenue, Huntington Beach, CA 92649 • 800/735-4328

ECO 14028 • 08-04-351C • © BSH Home Appliances Corp. 2001 • Litho U. S. A. 4/01