Vermont Castings VCS5005BI User Manual

VERMONT CASTINGS

INBUILT GAS BARBEQUE GRILL

USER MANUAL VCS5005BI

OWNERS INSTALLATION & OPERATING INSTRUCTIONS.

KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE.

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Congratulations on your purchase of this new Inbuilt Majestic barbeque. The
following information is designed to assist you in the assembly, installation,
operation, maintenance tips and trouble shooting and as well as some very
important safety information. We are sure that you will have many years of
enjoyable outdoor entertainment.

CONTENTS

Part 1: For Your Safety

Part 2: Installation Instructions

• Installation Warnings

• Clearances

• Gas Connections

• Safe Use of LPG Gas

• Safe Use of Natural

• Test for Leaks

Part 3: Operating Instructions

• Control Functions

• Lighting the Main Burners

• Turning Off the Burners

• Flare Ups

• Match Lighting the Main Burners

• Lighting the Rotisserie Burner

Part 4: Care & Maintenance

• Main Burners

• Rotisserie Burners

• Cooking Grids

• Drip Tray

• Stainless Panels

• Porcelain Ceramic Castings

• Burner Adjustments

Part 5: Troubleshooting

Part 6: Warranty

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Part 1: For Your Safety

For your safety do not operate this appliance before reading this
instruction book.

WARNING: Improper installation, adjustment, alteration, service or
maintenance can cause injury or property damage. For assistance or
additional information consult with Raypak Australia, your Raypak
distributor, qualified installer or accredited Rheem Australia Service
agency

WHAT TO DO IF YOU SMELL GAS?
DO NOT try to light any gas appliance.
DO NOT touch any electrical switch.

Turn off gas supply at meter.
Immediately call Rheem Service or your gas supplier or licensed gas fitter.
Note: Some gases are heavier than air and it maybe necessary to check for

gas leaks at floor level.

CAUTION!
DO NOT operate this appliance before reading this instruction booklet.
DO NOT place articles or objects on or against the appliance.
DO NOT store chemicals or flammable materials near this appliance.
DO NOT spray aerosols in the vicinity of this appliance whilst it is in

operation.

WARNING

 An LP gas cylinder not connected for use shall not be stored in the

vicinity of this or any other appliance.

 Always keep this Manual near the grill, for convenient future reference.

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WARNING

Barbeques must be used in accordance with the installation requirements of
your local gas supply authority, or the appropriate installation code issued by
the Australian Gas Association and the Australian Liquefied Petroleum Gas
Association.
Barbeques for use with bottled gas are labelled “Propane Gas” Barbeques for
use with natural gas are labelled “Natural Gas” and must be installed by an
authorised person. Check the gas type sticker attached to the barbeque.
Check that the label matches the gas type for the area in which it is to be
installed.

• Read the instructions before using the appliance.

• Accessible parts may be very hot.

• Keep young children away.

• Any modification of this appliance may be dangerous.

• Turn of the gas supply at the gas cylinder (LPG) after use.

• Parts sealed by the manufacture or their agents must not be

manipulated the user.

PREVENTION OF BURNS

 Always keep children and pets under close supervision when using the

grill, and never permit them to come near the grill while in use, as the
exterior surfaces will be very hot.

 Always wear insulated protective mitts when working at the grill, or

when attempting to close off the gas supply valve after cooking has
been completed, to prevent possible burns. Always use insulated pot
holders when handling containers of hot food.

 Always use an insulated mitt when adding a smoking agent to the

smoke box.

 Never store or use petrol or other flammable or volatile substances in

the vicinity of this grill or in the vicinity of any other heat generating
appliance.

VCS5005BINAU VCS5005BIPAU

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Natural Gas Propane

Gas Consumption 66 MJ/h 80 MJ/h

Test Point Pressure 1 kPa 2.75 kPa

Injector Diameters –

Main Burners

1.50 mm 1.02 mm

Injector Diameters –

Rotisserie Burner

2.10 1.10mm

Main Burner Aeration 4.5mm 6.35mm

Rotisserie Burner

Aeration

16mm 10mm

Number of Injectors 5 x Hot Plate 1 x Rotisserie 5 x Hot Plate 1 x Rotisserie

Weight Kg 90 90

Dimensions mm L 980 x D 620 x H 580 L 980 x D 620 x H 580

COMBUSTION AIR OPENINGS

There are 31 25mm x 7mm oblong combustion air openings
on the underside of the upper front panel and 1 x 26mm
diameter combustion air opening on the right hand lower panel and 1 x 26mm diameter
combustion air opening on the left hand lower panel.

Part 2: Installation Instructions

Installation Warnings

A safe location for use of this outdoor BBQ
DANGER: This appliance shall only be used in an above ground, open air

situation with natural ventilation without stagnant areas, where gas leakage
and products of combustion are rapidly dispersed by wind or natural
convection. This grill has been designed for outdoors only
Never install this grill inside any building, garage, shed or breezeway or inside
any boat, trailer or recreational vehicle to prevent a possible fire and to
prevent the possibility of carbon monoxide poisoning or asphyxiation.
Any enclosure in which this appliance is installed shall comply with one of the
following:

• An enclosure with walls on all sides, but at least one permanent
opening at the ground level and no over head cover.

• Within a partial enclosure that includes an over head cover and no
more than two walls.

• Within a partial enclosure that includes an over head cover and more
than two walls, the following shall apply:

a) at least 25 % of the total wall area is completely open; and
b) at least 30 % of the remaining wall area is open and
unrestricted.

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c) In case of balconies, at least 20% of the total of the side,
back and front wall areas shall be remain open and
unrestricted.

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CLEARANCES

This appliance must be installed on non combustible materials. This outdoor
Barbeque must be installed in accordance with AS5601.

Safe Use of LPG (Propane) Gas
DANGER:

 Never install a propane cylinder that is more than 80 % full, as the

contents may lack the adequate room for expansion when exposed to
heat. Propane vapour may then vent through the pressure relief valve,
which could accumulate in a pool and later cause an explosion or fire.

 Never store a spare propane cylinder in or near this grill.

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 Exposing a disconnected cylinder to heat could result in the venting of

the propane vapour through the pressure relief valve, and the pooled
vapour could result in a violent fire.

 Always confirm that all the openings in the cylinder compartment are

free from any obstructions that would restrict the circulation of
ventilation air. Good ventilation will prevent the pooling of leaked
propane vapour, which is heavier than air, and which could explode if
ignited.

WARNINGS:

 Always consult the rating label prior to the installation of this barbeque

to confirm which fuel the unit has been configured for and will be
suited for the gas that you have available.

 Always check that there are no gas leaks before lighting this grill. Apply

a 50/50 solution of liquid soap and water to the gas supply connections

with a brush or spray bottle, and watch for bubbles.
(tighten connections and check again) Never use a match or naked
flame to test for gas leaks.

 Always visually inspect the gas supply line for fraying, cracking or

rodent damage before each use of this grill and if necessary replace

the defective part.

 Always store your spare propane cylinder in an outdoor area that is

well ventilated, shady cool and removed from any heat source. Always

store in an upright position. Never store

a spare cylinder in the vicinity

of this grill, or in the vicinity of any other heat source.

Safe Use of Natural Gas

DANGER:

 Always consult the rating label prior to the installation of this barbeque
to confirm which fuel the unit has been configured for and will be suited
for the gas that you have available.
 The size of the gas line to the appliance (ref AS5601) & connection to
the natural gas supply must be carried out by a licensed plumber for
safety and to assure compliance with the applicable codes.

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 Note: This unit is supplied with a gas regulator, securing bracket and

screws which must be fitted during installation. Fig. 1

Fig. 1

 Always promptly shut off the gas supply and immediately extinguish all

flames if you smell gas. Contact your licensed plumber to rectify the gas
leak.

 Always check that there are no gas leaks before lighting this grill. Apply a

50 / 50 solution of liquid soap and water to the gas supply connections
with a brush or spray bottle, and watch for bubbles.

 Always visually check that there is no damage to the gas connections prior

to being used.

 Never permit a gas supply line to come in contact with any heated surface

of this grill.

Test for Leaks

 Always promptly shut off the gas supply and immediately extinguish all

flames if you smell gas. Contact your licensed plumber to rectify the gas
leak.

 Always check that there are no gas leaks before lighting this grill. Apply a

50 / 50 solution of liquid soap and water to the gas supply connections
with a brush or spray bottle, and watch for bubbles.

 Always visually check that there is no damage to the gas connections prior

to being used.

 Never permit a gas supply line to come in contact with any heated surface

of this grill

Part 3: Operating Instructions

CONTROL FUNCTIONS

Propane Tank Valve

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Warning: Never open the tank valve unless the grill is being prepared for
use. This will prevent the pooling of Propane vapour.

Always open the valve immediately before lighting the grill and always close it
immediately after cooking has been completed.

Burner Control Valve

On the model VCS5005 Barbeque there are 5 independent control valves for
the main burners and a separate control for the rotisserie burner. (see Fig.7)

The OFF position is indicated by the dot above each knob. A full range of
flame adjustment is available from High to Low by turning the knob anti­clockwise.

Electronic Ignition System

As you push the Ignitor Button, you will hear a series of clicks as the ignitor
module generates an ignition spark to the burners. The burner should light
within 4 seconds. The system is powered by a single “AA” battery. To remove
or replace the battery, turn the push button knob anti-clockwise and carefully
pull out the spring and battery. Ensure that the positive end of the battery is
in the down (bottom) position before replacing the knob.

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Note Aeration Settings: Natural gas model; Main burner aeration to be set
at 4.5 mm open .Rotisserie burner aeration to be set at 16 mm open Propane
model main burner aeration to be set a 6.35 mm Rotisserie burner to be set
at 10 mm open.

Turning the burners off

1. Always turn the burner control knob(s) to the OFF position when cooking
has been completed.

2. Promptly turn OFF the gas supply valve at the propane cylinder or the
isolation valve on the natural gas supply line.

3. Close the hood of the grill.

FLARE UPS

Flare ups sometimes occur when food droppings fall into the hot sear plates
or burners and ignite .Some flaring is normal and desirable, as it helps impart
the unique flavours associated with grilled foods. Controlling the intensity of
the flare ups is also desirable, however in order to avoid burned or unevenly
cooked foods and prevent the possibility of an accidental fire.

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WARNING Always monitor the grill carefully while cooking and turn down
the flame level down (LOW) or (OFF) if flare ups intensify.

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Part 4: Care & Maintenance

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Part 5: Troubleshooting

PROBLEM POTENTIAL CAUSE ACTION REQUIRED

Burner will not

light

Gas supply turned off

Out of Propane

Blockage in the gas system

Misalignment of the gas valve to the venturi

tubes of the burner

Improper attachment of the propane hose and

regulator

Turn on gas supply and re-try

Confirm the flow of gas by smell

or listening for the sound of the
gas being emitted. Allow gas to

clear before attempting to

relight.

Check that there is gas in the

cylinder

WARNING: Never take a

propane cylinder indoors for any

purpose

Confirm that the venturi tubes

are not blocked by insects of

other debris. Use a special

venturi brush to clean (Fig 16)

Use a pin or needle to carefully

probe the orifice in the gas

valve. Never enlarge the orifice.

(Fig 18)

Look under the control panel

and reinsert the gas injector into

the venturi tube if required (Fig

22)

Tighten the regulator connection

fitting into the cylinder valve.

This will be a left hand thread –

do not over tighten.

Unit will not heat

up (LPG)

Control knob left open at start up

Or

Turning gas on too quickly

For safety, the regulator
coupling on your barbeque is
equipped with a flow control

mechanism. This device limits

the flow of gas in the event of a

sudden change in demand for

gas. This may be engaged

inadvertently, if a burner control

knob should be left ON when

you open the gas cylinder valve.

Rapidly opening the valve can

also engage flow control. To

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resolve the problem, close your

cylinder valve. Confirm that all

burner control knobs are in the

OFF position. Open the cylinder
valve slowly (about 1 to 2 turns)
and wait 5 seconds. Finally, turn

a single burner ON and try

relighting it.

Unit won’t stay lit Wind

Running out of gas

Always shelter your barbeque

from strong winds.

Confirm the flow of gas by smell

or by listing for the sound of the

gas being emitted.

Weigh you propane cylinder. A

standard 9 Kg bottle will weigh

approximately 8 Kg when empty

and approximately 17 Kg when

it is 80% full.

Warning: Never take a propane
cylinder indoors for any purpose.

Uneven burn

pattern

or

Flash back fire

Blockage in the burner of gas system

Corroded burner

Confirm that the venturi tubes

are not blocked by insects of

other debris. Use a special

venturi brush to clean (Fig 16)

Use a pin or needle to carefully

probe the orifice in the gas

valve. Never enlarge the orifice.

(Fig 18)

Use a small nail or toothpick to

clean the burner ports (Fig 18)

Corrosion of a gas burner can

cause the solid material between

the gas ports to deteriorate,
resulting in uneven burning.

Contact Rheem spare parts for

the appropriate replacement

burner.

Excessive yellow

flame

Improper air shutter opening Your grill should burn with a

predominantly blue flame. If the
flame is mostly yellow, check the
venturi tubes for obstruction and

clean as shown on page 15. If

yellow flame still persist contact

Rheem Service on 131 031.

Flare Up Excessively fatty foods

Grease build up

Trim all excess fat from meat

before cooking.

Confirm that the sear plate is

clean and properly installed.

Remove excess grease from the

burner chamber.

Ignitor does not

spark

Electrode fouled

Wipe the electrode with a soft

clean cloth.

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Electrode cracked

Lead wire is disconnected

Lead wire is cracked

Battery dead or installed incorrectly

The electrode should be located
3 to 4 mm from the burner and

positioned to spark to the edge

of the gas port. If the spark gap

is incorrect or the unit is not

sparking properly call Rheem

Service on 131 031.

Replace electrode. Call Rheem

Service on 131 031.

Confirm that the lead wire from

the ignitor module to the

electrode is well seated on the

termination of the module.

Replace lead wire. Contact

Rheem Service on 131 031 for

lead wire replacement.

The battery in the Ignitor Button

maybe dead or installed

incorrectly. Correct position is

positive end down.

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Part 6: Warranty

RAYPAK/VERMONT CASTINGS BARBEQUE WARRANTY

AUSTRALIA ONLY

Rheem* will:

a) Repair or, if necessary replace any Raypak barbeque model VCS5005BI

or

b) Replace any component (or, if necessary, arrange the installation of a

barbeque which falls within the warranty periods specified below, in
accordance with and subject to the following table, conditions and
exclusions

Installation Model Period Warranty

From date of installation

Outdoor

Barbeque

Inbuilt

VCS5005BI Year 5 parts This warranty covers all parts

for 5 years and 12 months

labour, excluding grill plates,

flame tamer and ignition

system which are provided

with a 12 months warranty.

Notes:

*Rheem provides warranty service on behalf of Raypak Australia Pty Ltd.
**Refer to item 5 of warranty conditions.

Rheem reserves the right to transfer fully functional components from the
defective barbeque to the replacement barbeque if required.

In addition to this warranty, the Trade Practices Act 1974 and similar laws in
each state and territory provide the owner under certain circumstances with
minimum statutory rights in relation to your Raypak barbeque. This warranty
must be read subject to that legislation and nothing in this warranty has the
effect of excluding, restricting or modifying those rights.

RHEEM AUSTRALIA PTY LTD

A.B.N 21 098 823 511

RAYPAK AUSTRALIA PTY LTD

A.B.N 65 078 743 414

FOR SERVICE TELEPHONE

131 031 AUSTRALIA

0800 657 335 NEW ZEALAND

or refer to local Yellow Pages

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RAYPAK/VERMONT CASTINGS BARBEQUE WARRANTY

AUSTRALIA ONLY

WARRANTY CONDITIONS

1. This warranty is applicable only to this barbeque manufactured
from 1

st

May 2005.

2. This barbeque must be installed in accordance with the Raypak
barbeque installation instructions, supplied with the barbeque and
in accordance with all relevant statutory and local requirements of
the State in which the barbeque is installed.

3. This barbeque must be correctly commissioned by a licensed and
authorised person and the installation certified by the relevant Gas
Authority of the State in which the barbeque is installed.

4. Where a failed component or barbeque is replaced under warranty,
the balance of the original warranty period will remain effective.
The replaced part or barbeque does not carry a new warranty.

5. Where the barbeque is installed outside the boundaries of a
metropolitan area as defined by Rheem or further than 25 km from
a regional Rheem branch office or Accredited Service Agent, the
cost of transport, insurance and travelling costs between the
nearest Rheem Accredited Service Agent’s premises and the
installed site shall be the owner’s responsibility.

6. The warranty only applies to the barbeque and original or genuine
(company) component replacement parts and therefore does not
cover and plumbing or electrical parts supplied by the installer and
not an integral part of the barbeque.

WARRANTY EXCLUSIONS

1. REPAIR AND REPLACEMENT WORK WILL BE CARRIED OUT AS SET

OUT IN THE RAYPAK BARBEQUE WARRANTY, HOWEVER, THE
FOLLOWING EXCLUSIONS MAY CAUSE THE BARBEQUE WARRANTY TO
BECOME VOID AND MAY INCUR A SERVICE CHARGE AND/OR COST OF
PARTS.

a) Accidental damage to the barbeque or any component, including: Acts

of God, failure due to misuse, incorrect installation, attempts to repair
the barbeque other than by a Rheem Accredited Service Agent or the
Rheem Service Department.

b) Where it is found there is nothing wrong with the barbeque; where the

complaint is related to faulty plumbing; and not the barbeque or
barbeque components; where there is a failure of gas, electricity
supplies; where the supply of gas, electricity does not comply with the
relevant codes or acts.

c) Where the barbeque or barbeque component has failed directly or

indirectly as a result of: misuse or neglect.

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d) Where the barbeque is located in a position that does not comply with

the Raypak barbeque installation instructions or relevant statutory
requirements, causing the need for major dismantling or removal of
cupboards, doors, walls or use special equipment to bring the
barbeque to floor or ground level or to a serviceable position.

2. SUBJECT TO ANY STATUTORY PROVISIONS TO THE CONTRARY, THIS

WARRANTY EXCLUDES ANY AND ALL CLAIMS FOR DAMAGE TO
FURNITURE, CARPETS, WALLS, FOUNDATIONS OR ANY OTHER
CONSEQUENTIAL LOSS EITHER DIRECTLY OR INDIRECTLY DUE TO
MISUSE OF THE BARBEQUE, OR DUE TO LEAKAGE FROM FITTINGS
AND/OR PIPEWORK OF METAL. OTHER MATERIALS CAUSED BY
TEMPERATURE, WORKMANSHIP OR OTHER MODES OF FAILURE.

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MAJESTIC

VCS5005 ASSEMBLY PROCEEDURES

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GENERAL INFORMATION

FRAMING DIMENSIONS

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Fig 1

Non Combustible Clearances

Reference mm

A 604
B 101
C 50 dia
D 229
E 54

F 77

I 228

J 1110
N 478
O 102

Fig 2

NOTE: This BBQ must be installed in an enclosure
constructed from non-combustible material.

Clearances

See Fig 1 and Fig 2.

Specifications

Appliance specifications can be found on the data plate attached to the unit.

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VCS5005 ASSEMBLY DRAWING

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VCS5005 PARTS LIST

Distributed by
Raypak Australia
(Division of Rheem Australia Pty Ltd)
39 Koornang Rd
Scoresby Vic 3179

Ph 03 9757 3333
Fax [phone]
ABN 65078 743 414

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