Versa Flame BY12-084-029-97 Assembly & Operating Instructions

BY12-084-029-97 Eng 1 of 44 20111105–V0

Versa*FlameTM Gas & Charcoal Grill

Models Number: BY12-084-029-97

ASSEMBLY & OPERATING INSTRUCTIONS

For Outdoor Use Only

z This instruction manual contains important information necessary for the

proper assembly and safe use of the appliance.

z Read and follow all warnings and instructions before assembling/using

the appliance.

z Follow all warnings and instructions when using the appliance.
z Keep this manual for further reference

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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 fire department

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

DANGER

(a) Do not store a spare LP-gas cylinder under or near this appliance;
(b) Never fill the cylinder beyond 80 percent full; and
(c) If the information in (a) and (b) is not followed exactly, a fire causing
death or serious injury may occur.

SAFETY LABELS

DANGER: Indicates an imminently hazardous situation which, if not avoided, will

result in death or serious injury

WARNING: Be alert to the possibility of serious bodily injury if the instructions are not

followed. Be sure to read and carefully follow all of the messages.

CAUTION: Indicates a potentially hazardous situation, which, if not avoided, may

result in minor or moderate injury.

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GAS GRILL GENERAL WARNINGS

WARNING

z This outdoor cooking gas appliance shall be used only outdoors and shall not be

used in a building, garage or any other enclosed area.

z This outdoor cooking gas appliance is not intended to be installed in or on boats.

For other than RV grills, this appliance is not intended to be installed in or on
recreational vehicles.

z Use your grill OUTDOORS in a well ventilated space away from dwellings or other

buildings to prevent dangers associated with gas accumulation and toxic vapors.
The grill should be situated at least 60 inches (153 cm) from buildings. Not adhering
to these clearances will prevent proper ventilation and may increase the risk of a fire
and/or property damage, which could also result in personal injury.

z Maintain a minimum clearance of 60

inches (153 cm) between all sides of
grill, deck railings, walls or other
combustible material. DO NOT use
grill under overhead unprotected
combustible construction.

z DO NOT obstruct the flow of

combustion/ventilation air.

z DO NOT leave the grill unattended

while in use.

z DO NOT use while under the influence

of drugs or alcohol.

z Keep the fuel supply hose away from heated surfaces.
z DO NOT put grill in storage or move it immediately after use. Allow grill to cool to

touch before moving/storing. Failure to do so could result in fire resulting in property
damage, personal injury or death.

z The appliance is for household use only. DO NOT use this grill for other than its

intended purpose.

z Never use natural gas in a unit designed for liquid propane gas.
z Never use charcoal or wood briquettes in a gas grill. Flavoring chips must be

contained in a metal smoking box to contain ash and prevent fires.

z Leak test must be conducted prior to each use.
z Keep a fire extinguisher on hand acceptable for use with gas products. Refer to your

local authority to determine proper size and type.

z Grill is hot when in use. To avoid burns:

z DO NOT attempt to move the grill.
z Wear protective gloves or oven mitts.
z DO NOT touch any hot grill surfaces.
z DO NOT wear loose clothing or allow hair to come in contact with grill.

z Never close the SIDE BURNER LID during operation.

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USE OF LP GAS CYLINDER AND INSTALLATION
BEFORE INSTALLING:

The installation must conform with local codes or, in the absence of local codes, with
either the National Fuel Gas Code, ANSI Z223.1/NFPA 54, 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.

BEFORE EVERY USAGE:

Be sure to inspect the hose for leaks, cuts, wear, abrasion, or damage of any sort before
using this appliance. If any damage is apparent the hose must be replaced with a
replacement hose specified by the manufacturer before it is put in use.

LP GAS CYLINDER

The LP (liquid propane) cylinder specifically designed to be used with this unit MUST have
a 20 lb. (9.1kg) capacity with a Type 1 cylinder value and an overfilling protection device
(OPD). Only use LP cylinders with this type of valve.
The nominal cylinder: Height = 18 inches (45.7 cm), Diameter = 12 inches (30.5cm) and
bottom ring diameter = 8 inches (20.3 cm)

LP tank valve must have:

z Type 1 outlet compatible with regulator or appliance.
z Safety relief valve.
z UL listed Overfill Protection Device(OPD). This OPD safety

feature is identified by a unique triangular hand wheel. Use only
tanks equipped with this type of valve.

z LP tank must be arranged for vapor withdrawal.

The LP cylinder must be constructed and marked in

accordance with the Specifications for LP-Gas Cylinders of
the U.S. Department of Transportation (D.O.T.) or the
National Standard of Canada CAN/CSA – B339, Cylinder,
Spheres and Tubes for Transportation of Dangerous Goods;
and Commission of Dangerous Goods; and Commission, as
applicable.

z The LP cylinder must include a collar to protect the cylinder

valve.

z The LP cylinder must be stored outdoors out of the reach of children and pets. It

SHALL NOT be stored in a building, garage, shed, breezeway, or any other enclosed
space. Cylinders can be stored indoors ONLY if cylinders are disconnected and
removed from the appliance.

z The cylinder should ALWAYS be put in an upright position.

WARNING

Place dust cap on cylinder valve outlet whenever the cylinder is not in use. Only install

the type of dust cap on the cylinder valve outlet that is provided with the cylinder valve.

Other types of caps or plugs may result in leakage of propane.

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DANGER

z DO NOT connect this grill to an existing #510 POL cylinder valve with Left hand

threads. The Type 1 valve can be indentified with the large external threads on the
valve outlet.

z DO NOT connect to a propane cylinder exceeding this capacity.
z DO NOT connect to a cylinder that uses any other type of valve connection device.
z Never store a spare LP gas cylinder under or near your grill. This could cause

pressure to be expelled through the vapor relief valve resulting in fire, explosion, or
severe personal injury including death.

z Keep the ventilation opening(s) of the LP gas cylinder enclosure free and clear from

obstructions and debris.

z DO NOT insert any foreign objects into the valve outlet. Damage to the back-check

could result. A damaged back-check can cause a leak, possibly resulting in
explosions, fire, severe bodily harm, or death.

z Place dust cap on cylinder valve outlet whenever cylinder is not in use. Only install

the type of dust cap on the cylinder valve outlet that is provided with the cylinder
valve. Other types of caps or plugs may result in leakage of propane.

WARNING

FOR FILLING THE LP GAS CYLINDER

z Allow only qualified LP gas dealers to properly fill or repair your LP cylinder.
z DO NOT allow the cylinder to be filled beyond 80% capacity. Over-filled tanks can

create a dangerous condition. Over-filled tanks can build-up pressure and cause the
relief valve to expel propane gas vapors. The vapor is combustible and if it comes in
contact with a spark source or flame an explosion causing severe burns, bodily
harm, or death could occur.

z Always use a safety cap when grill is not connected to cylinder.
z If you exchange a cylinder with a qualified exchange program, be sure the cylinder

has a Type 1 valve and an over-filling prevention device (OPD).

INSTALLING GAS CYLINDER

1. Check that cylinder valve is closed by turning knob

clockwise.

2. Place the gas cylinder onto the base hole of

bottom shelf and position it where the valve
opening faces side burners and make sure the
hose is not kinked/damage or touch any hot
surface.

3. Lock the gas tank with the locking bolt on the right

edge of bottom shelf.

4. Attach the regulator to the gas cylinder valve.

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WARNING

Keep the fuel supply hose away from any heated surfaces.

WARNING

z The pressure regulator and hose assembly supplied with your gas grill must be

used. Replacement pressure regulators and hose assemblies must be those
specified by the grill manufacturer.

z Do not attempt to connect it to any other fuel supply source.
z Do not attempt to adjust or repair the regulator. The regulator is designed to operate

at the maximum output pressure of 11 inches of water column (2.74 kPa).

CONNECTION PROCEDURES

Connecting Regulator to the LP Tank

1. Place LP tank on a secure, level, and stable surface.

2. Turn control knob to the OFF position.

3. Turn LP tank OFF by turning OPD hand wheel clockwise to a
full stop.

4. Remove the protective cap from the LP
tank valve. Always use dust cap and
strap supplied with valve.

5. Hold regulator, insert nipple (B) into LP
tank valve. Hand tighten coupling nut,
holding regulator in a straight line (C)
with LP tank valve so as not to cross
thread the connection.

6. Turn the coupling nut clockwise to tighten to a full solid stop. The regulator will seal on
the back-check feature in the LP tank valve, resulting in some resistance. An additional
one-half to three quarters turn is required to complete connection. Tighten by hand
only – do not use tools.

NOTE: If you cannot complete connection, disconnect regulator and repeat step 5 and 6. If
you are still unable to complete the connection, do not use this regulator!

To disconnect LP gas cylinder:

WARNING

z If the grill is not in use, the gas must be turned off at the supply cylinder(s). Storage of

the grill is permissible only if the cylinder is disconnected and removed from the grill.

z Cylinders must be stored outdoors out of the reach of children and pets and must not

be stored in a building, garage or any other enclosed area.

Do not use a POL transport plug (A)
(plastic part with external threads)! It
will defeat the safety feature of the
valve.

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1. Turn the burner valves off.

2. Turn the tank valve off fully (turn clockwise to stop).

3. Detach the regulator assembly from the tank valve by turning the quick coupling nut

counterclockwise.

LEAK TEST

WARNING

z DO NOT SMOKE WHILE CONDUCTING LEAK TEST.
z NEVER PERFORM LEAK TEST WITH AN OPEN FLAME.
z Perform test OUTDOORS only in a well ventilated area.
z If it is evident there is excessive abrasion or wear, or the hose is cut, it must be

replaced prior to the appliance being operational. The replacement hose shall be

specified the by manufacturer.
When to perform a leak test:
z After assembling the grill and before lighting for the first time, even if purchased

fully assembled.
z Every time the LP gas cylinder is refilled or if any of the gas components are

replaced.

Checking for leaks:

1. Create a mixture of 50% water and 50% liquid dishwashing soap.

2. Open the lid.

3. Ensure all control knobs are set to the “OFF” position.

4. Turn on the fuel supply at the cylinder valve. Turn the cylinder valve knob one turn
counter-clockwise.

5. Apply the soap water mixture to the following:

a. Supply tank weld.
b. Connection nut to tank valve.
c. Back side of connection nut to brass nipple.
d. Brass nipple connection into regulator.
e. Regulator connections to gas supply hoses.
f. Gas supply hose connection.
g. Side burner valve stem cap
h. Side burner connection to hose.
i. Hose connection to gas manifold.
j. The full length of gas supply hose.
k. Tank valve to cylinder.

6. Check each place (a-k) for growing bubbles which indicates a leak.

7. Turn off gas supply at cylinder valve.

8. Turn on control knobs to release gas pressure in hose.

9. Turn control knobs to “OFF” position.

10. Tighten any leaking connections.

11. Repeat soapy water test until no leaks are detected.

12. Turn off gas supply at cylinder valve until you are ready to use your grill.

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LIGHTING INSTRUCTIONS

BEFORE LIGHTING

WARNING

z Inspect the gas supply hose prior to turning the gas “ON”.
z If there is evidence of cuts, wear, or abrasion, it must be replaced prior to use.
z Do not use the grill if the odor of gas is present.
z Only the pressure regulator and hose assembly supplied with the unit should be

used.

z Perform the “LEAK TEST” according to instruction before operating the grill.
z ALWAYS keep your face and body as far away from the burner as possible while

lighting.

LIGHTING THE MAIN BURNER OF GRILL

1.Read all instructions before lighting.

2.Open lid during lighting.

3.Light the IGNITION BURNER first. Push and turn main burner knob slowly to HI. Burner

should light immediately.

4. Once the IGNITION BURNER is lit, you may light the rest of burners.

5. If ignition does not occur in 5 seconds, turn the knob(s) off, wait 5 minutes, then repeat

the lighting procedure.

6. To turn burners off, turn the control knobs clockwise until they lock in the OFF

position.Turn gas supply to OFF.

Light this burner first! Turn

counterclockwise to open

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LIGHTING THE SIDE BURNER (Side burner):

DANGER

Never close the SIDE BURNER LID during operation

1. Read all instructions before lighting.

2. Open lid during lighting.

3. Push and turn main burner knob slowly to HI. The side
burner should light immediately.

4. Once burner is lit, continue to push and hold control knob
for 45 seconds.

5. If ignition does not occur in 5 seconds, turn the knob off,
wait 5 minutes, then repeat the lighting procedure or light
by match.

6. To turn burners off, turn the control knob clockwise until it locks in the OFF position.
Turn gas supply to OFF.

MATCH LIGHTING THE MAIN BURNERS:

1. Turn OFF all burner valves.

2. Make sure the lid is open.

3. Place a lighted match between the coils on

the extension rod and hold next to the
burner.

4. Turn the control knob(s) to the “HI/Light”

osition. Burner should light immediately.

5. For infra-red side burner, once the burner is

lit continue to push and hold control knob for
45 seconds.

6. If the burner does not light in 4 seconds turn

the knob off, wait 5 minutes and repeat above procedures.

MATCH LIGHTING THE SIDE BURNER:

1. Turn OFF all burner valves.

2. Make sure the lid is open.

3. Strike and carefully palce a long match 1/2” (1 to 2 cm) from

the side burner

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4. Turn the control knob to the “HI/Light” position. Burner should light immediately.

5. Once the burner is lit continue to push and hold control knob for 45 seconds.

6. If the burner does not light in 4 seconds turn the knob off, wait 5 minutes and repeat above

procedures.

7.

DANGER

z Keep your face and hands as far away from the grill as possible when lighting it.

FLAME CHARACTERISTICS

This procedure outlines how to check for proper
burner flame characteristics.
Burner flames should be blue and stable with little
yellow tips, with no excessive noise, or lifting. If the
flame is yellow, it indicates insufficient air. If the
flame is noisy and tends to lift away from the
burner, it indicates too much air. If any of these
conditions exist call our customer service line.
Visually check the burner flames prior to each use.
The flame should look like this picture. If they do
not, refer to the burner maintenance part of this
manual.

MAINTENANCE GUIDE

Before cleaning the grill, place it in an area clear and free from combustible materials,
gasoline and other flammable vapors and liquids.
Do Not obstruct the flow of combustion and ventilation air.

GRILL RACK

The easiest way to clean the grill is immediately after cooking is completed and after turning
off the flame. Wear a barbeque mitt to protect your hand from the heat and steam. Dip a
brass bristle barbeque brush in tap water and scrub the hot grill. Dip the brush frequently in
the bowl of water. Steam, created as water hits the hot grill, assists the cleaning process by
softening any food particles. The food particles will “fall off” and burn. If the grill is allowed to
cool before cleaning, cleaning will be more difficult.

GREASE TRAY

The grease tray should be emptied and wiped down periodically and washed with a mild
detergent and warm water solution. A small amount of sand or cat litter may be placed in
the bottom of grease tray to absorb the grease. Check the grease tray frequently. Don’t
allow excess grease to accumulate and overflow out of the grease tray.

GRILL BURNERS

Extreme care should be taken when removing a burner as it must be correctly centered on
the orifice before any attempt is made to re-light the grill. Frequency of cleaning will depend
on how often you use the grill.

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Spiders and small insects occasionally spin webs or make nests in the grill burner tubes
during transit and warehousing. These webs can lead to gas flow obstruction which could
result in a fire in and around burner tubes. This type of fire is known as flashback and can
cause serious damage to your grill and create an unsafe operating condition for the user.
Although an obstructed burner tube is not the only cause of flashback, it is the most
common cause. To reduce the chance of flashback, you must clean the burner tubes
before assembling your grill, and at least once a month in late summer or early fall when
spiders are most active. Also, perform this burner tube cleaning procedure if your grill has
not been used for an extended period of time.

You should inspect the burners at least once a year or immediately after any of the
following conditions occur:

1. The smell of gas in conjunction with the burner flames appearing yellow.

2. The grill does not reach temperature.

3. The grill heats unevenly.

4. The burners make popping noises.

WARNING

z ENSURE that the gas supply and the knobs are in the “OFF” position.

Cleaning The Burner Tubes and Burner Ports (For main burners)

To reduce the chance of FLASHBACK FIRE you must clean the Burner Tubes as follows
at least once a month in summer and fall or whenever spiders are active in your area, and if
your grill has not been used for an extended period of time.

Removing the main burner(s):

1. Turn all Burner Valves to the full OFF position.

2. Turn the LP Gas tank valve to the full OFF position.

3. Detach the LP Gas regulator assembly from your gas
cylinder.

4. Remove the Cooking Grates and Heat Distribution
Plates from your grill.

5. Remove the screw from the front of each Burner using a
Phillips Head Screwdriver.

6. Carefully lift each Burner up and away from the Gas
Valve Orifice.

7. Check and clean burner/ venturi tubes for insects and
insect nests. A clogged tube can lead to a fire beneath
the grill.

8. Bend a stiff wire or wire coat hanger into a small hook as shown and run the hook
through the Burner Tube and inside the Burner
several times to remove debris.

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WARNING

For safe operation ensure the Gas Valve Assembly
Orifice is inside the Burner Tube before using your
grill. See figure. If the Orifice is not inside the
Burner Tube, lighting the Burner may cause
explosion and/ or fire resulting in serious bodily
injury and/or property damage.

When an appliance is supplied on casters and is connected to the supply piping by means
of a connector for movable appliances, the operator shall be aware there is a restraint on
the appliance and, if disconnection of the restraint is necessary, to reconnect this restraint
after the appliance has been returned to its originally installed position.

Cleaning The Infrared side burner

1. Turn all Burner Valves to the full OFF position.

2. Turn the LP Gas tank valve to the full OFF position.

3. Detach the LP Gas regulator assembly from your gas cylinder.

4. Remove the Cooking Grates from the side burner.

5. Remove the mounting screws at the back of side burner.

6. Slide the infrared burner out of the enclosure.

7. Check and clean burner/ venturi tubes for insects and insect nests. A clogged tube can

lead to a fire beneath the grill.

8. Bend a stiff wire or wire coat hanger into a small hook as shown and run the hook

through the Burner Tube and inside the Burner several times to remove debris.

WARNING

For safe operation ensure the Gas Valve Assembly Orifice is inside
the Burner Tube before using your grill. See figure. If the Orifice is
not inside the Burner Tube, lighting the Burner may cause
explosion and/ or fire resulting in serious bodily injury and/or
property damage.

CAUTION

z Keep outdoor cooking gas appliance area clear and free from combustible materials,

gasoline and other flammable vapors and liquids.

z Do not obstruct the flow of combustible and ventilation air.
z Keep the ventilation openings of the cylinder enclosure free and clear of debris.

z Check and clean burner/venturi tubes for insects and insect nests. A clogged tube

can lead to a fire beneath the grill.

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CHARCOAL GRILL GENERAL WARNINGS

WARNING

z The maximum weight of charcoal to be used is 2.4lb (1.1kg). Too much

charcoal may cause the gas component to overheat and malfunction.

z The charcoal chamber is for charcoal cooking only. Gas grill and side burner

cannot be used for charcoal cooking.

z Only use this grill on a hard, level, non-combustible, stable surface (concrete,

ground etc.) capable of supporting the weight of the grill. Never use on wooden
or other surface that could burn.

z DO NOT use grill without charcoal ash tray in place. DO NOT attempt to

remove charcoal ash tray while tray contains hot coals.

z Use your grill OUTDOORS in a well ventilated space away from dwellings or

other buildings to prevent dangers associated with gas accumulation and toxic
vapors. The grill should be situated at least 60 inches (153cm) from buildings.
Not adhering to these clearances will prevent proper ventilation and may
increase the risk of a fire and/or property damage, which could also result in
personal injury.

z Maintain a minimum clearance of 60 inches (153 cm) between all sides of grill,

deck railings, walls or other combustible material. DO NOT use grill under
overhead unprotected combustible construction.

z For outdoor use only. Do not use this grill for other than its intended purpose.
z For household use only. Do not use this grill for other than its intended purpose.
z We recommend the use of a Charcoal Chimney Starter to avoid the dangers

associated with charcoal lighting fluid.

z Use charcoal chimney starter or charcoal that has been pre-treated with lighter

fluid when starting fire in charcoal section of your grill.

z Do not store lighter fluid or other flammable liquids, material or charcoal that

has been pre-treated with lighter fluid under the grill or inside stroage shelves.

z Do not use gasonline or alcohol for lighting charcoal. Use of any of these or

similar products could cause an explosion possibly leading to severe bodily
injury.

z Never add charcoal lighting fluid to hot or even warm coals as flashback may

occur causing severe burns.

z Place grill in an area where children and pets cannot come into contact with

unit. Close supervision is necessary when grill is in use.

z Do not leave grill unattended when in use.
z When adding charcoal and/or wood, use extreme caution and follow instruction

in Adding Charcoal / Wood During Cooking section of this manual.

z Do not store or use grill near gasoline charcoal or other flammable liquids or

where flammable vapors may be present.

z Use caution when adjusting charcoal grate height. Handle may be hot when in

use.

z Use caution since flames can flare-up when fresh air suddenly comes in

contact with fire. When opening the lid, keep hands, face and body a safe
distance from hot steam and flame flare-ups.

z Extinguished coals and ashes should be placed a safe distance from all

structures and combustible materials.

z Never raise or lower charcoal grate when water is smoking as hot water may

splash onto coals.

z Use caution since flames can flare-up when fresh air suddenly comes in

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contact with fire. When opening the lid, keep hands, face and body a safe
distance from hot steam and flame flare-ups.

z After each use, clean the grill thoroughly and apply a light coat of vegetable oil

to the interior to prevent rusting. Cover the grill to protect it from excessive
rusting.

z Grill is hot when in use. To avoid burns:

z DO NOT attempt to move the grill
z Wear protective gloves or oven mitts.
z DO NOT touch any hot grill surfaces.
z DO NOT wear loose clothing or allow hair to come in contact with grill.

PREPARATION FOR USE & LIGHTING INSTRUCTIONS

WARNING

OUTDOOR USE ONLY. DO NOT OPERATE GRILL INDOORS OR IN AN ENCLOSED SPACE

Never use grill indoors. Carbon Monoxide poisoning can lead to death.

Curing your grill

Prior to your first use of the Grill, follow the instructions below carefully to cure your grill. Curing
your grill will minimize damage to the exterior finish as well as rid the grill of paint odor that can
impart unnatural flavors to the first meal prepared on the grill.

IMPORTANT: To protect your grill from excessive rust, the unit must be properly cured and

covered at all times when not in use.

Step 1

Lightly coat all interior surfaces of the grill with vegetable oil or vegetable oil spray.

Step 2

Follow the instructions below carefully to build a fire. You may use charcoal and/or wood as fuel for
the grill (see “Adding Charcoal/Wood During Cooking” section of this manual).

WARNING

Use only a high grade plain charcoal or charcoal /wood mixture.

NOTE: To extend the life of your grill, make sure that hot coals and wood do not touch the
walls of grill.

IF USING CHARCOAL CHIMNEY STARTER, PROCEED TO STEP 5.

If you choose to use charcoal lighting fluid, ONLY use charcoal lighting fluid approved for lighting
charcoal. Do not use gasoline, kerosene, alcohol or other flammable material for lighting charcoal.
Follow all manufacturer’s warnings and instructions regarding the use of their product. Start with

3.3 lb(1.5 kg ) of charcoal. This should be enough charcoal to cook with, once the curing process

has been completed. Place the charcoal in the center of each charcoal grate.

Step 3

Saturate charcoal with lighting fluid. With lid open, wait 2 to 3 minutes to allow lighting fluid to soak
into charcoal. Store lighting fluid a safe distance from the grill.