weber S-640 User Manual

GAS GRILL

Built-In Natural Gas Grill Installation Guide

THIS GAS APPLIANCE IS DESIGNED FOR OUTDOOR USE ONLY.

S-440
S-640

# 43168

YOU MUST READ THIS OWNER’S GUIDE

BEFORE OPERATING YOUR GAS GRILL

 DANGER

If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open fl ames.

3. Open lid.

4. If odor continues, keep away from the
appliance and immediately call your gas
supplier or your fi re department.

Leaking gas may cause a fi re or explosion
which can cause serious bodily injury or death,
or damage to property.

 WARNING:

1. Do not store or use gasoline or other
fl ammable 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.

 WARNING: Follow all leak-check procedures

carefully in this manual prior to barbecue
operation. Do this even if the barbecue was
dealer-assembled.

NOTICE TO INSTALLER: These instructions
must be left with the owner and the owner
should keep them for future use.

THIS GAS APPLIANCE IS DESIGNED FOR
OUTDOOR USE ONLY.

 WARNING: Do not try to light this appliance

without reading the “Lighting Instructions”
section of this manual.

43168 US 01/30/07

NG

2

WARNINGS

DANGER

Failure to follow the Dangers, Warnings and Cautions con­tained in this Owner’s Manual may result in serious bodily
injury or death, or in a fi re or an explosion causing damage to
property.

WARNINGS

 Do not store a spare or disconnected liquid propane cylinder

under or near the barbecue.

 Improper assembly may be dangerous. Please carefully

follow the assembly instructions in this manual.

 Do not operate the Weber® gas barbecue if there is a gas leak

present.

 Do not use a fl ame to check for gas leaks.
 Combustible materials should never be within 24 (60.96cm)

®

inches of the top, bottom, back or sides of your Weber

gas

barbecue.

 Do not put a barbecue cover or anything fl ammable on, or in

the storage area under the barbecue.

 Your Weber® gas barbecue should never be used by children.

Accessible parts of the barbecue may be very hot. Keep
young children away while it is in use.

 You should exercise reasonable care when operating your

Weber® gas barbecue. It will be hot during cooking or
cleaning and should never be left unattended, or moved
while in operation.

 Liquid propane gas is not natural gas. The conversion or

attempted use of natural gas in a liquid propane unit or liquid
propane gas in a natural gas unit is dangerous and will void
your warranty.

 Do not attempt to disconnect any gas fi tting while your

barbecue is in operation.

 Keep any electrical supply cord and the fuel supply hose

away from any heated surfaces.

 Do not use this Weber

®

tank enclosure kit unless all parts are
in place. The unit must be properly assembled according
to the instructions outlined in the “Assembly Instruction”
section of the Owner’s Guide.

LIQUID PROPANE GAS UNITS ONLY:

®

 Use the regulator that is supplied with your Weber

Tank

Enclosure Kit.

 Do not attempt to disconnect the gas regulator or any gas

fi tting while your barbecue is in operation.

 A dented or rusty liquid propane cylinder may be hazardous

and should be checked by your liquid propane supplier. Do
not use a liquid propane cylinder with a damaged valve.

 Although your liquid propane cylinder may appear to be

empty, gas may still be present, and the cylinder should be
transported and stored accordingly.

 If you see, smell or hear the hiss of escaping gas from the

liquid propane cylinder:

1. Move away from liquid propane cylinder.

2. Do not attempt to correct the problem yourself.

3. Call your fi re department.

BUILT-IN CUTOUT DIMENSIONS

LOCATING YOUR GRILL

When determining a suitable location for your Summit® gas grill installation, give attention
to concerns such as exposure to wind, proximity to traffi c paths, and keeping any
gas supply lines as short as possible. Never locate the Summit
breezeway, shed, under an unprotected overhang, or other enclosed area. Locate the grill

and structure so there is enough room to safely evacuate the area in case of a fi re.

CLEARANCE FROM SURFACES OR STRUCTURES

WARNING: Clearance from any surface or structure is 24
inches (609.6 mm) from the back and sides of the grill. Refer to
“Typical Gas Supply Installation” before starting installation.

WARNING: The structure, “island”, countertops, and adjacent
work areas for the built-in grill installation must be built from

noncombustible materials only.

NOTE: If you have questions on what materials are considered
noncombustible, contact your local building materials supplier or fi re
department.

®

gas grill in a garage,

1

1 1

2

a

b

CLEARANCES

24˝ inches (610 mm) Any Surface

1

27˝ inches (685.8 mm) min. for lid clearance

2

Grill Frame

a

Note: For a countertop treatment: Recommended 3/4˝ (19.1 mm)

b

overhang. Notch front edge for frame to fully slide in.

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BUILT-IN CUTOUT DIMENSIONS

3

BUILT-IN STRUCTURE CUTOUT DIMENSIONS

ALL DIMENSIONS ARE TO FINISHED SURFACES.

3

2

1

GENERAL CONSTRUCTION DETAILS

Summit® Built-In unit and all other accessory units should be on site
before construction begins.

All dimensions have a tolerance of plus or minus (+/-)
(.635 mm).
The grill frame rests directly on the Island Structure top
fi nished surface. Make sure this surface is level. Do not
support the grill from the bottom.

If the supporting structure is going to have an electrical outlet
for a rotisserie, it should be on the left side of the structure.

Refer to Summit® Built-In Tank Drawer Installation Instructions
for complete gas line locations.

1

/

4

inch

 WARNING: All countertop fi nished surfaces must be
constructed of a noncombustible material.

3

BUILT-IN CUTOUT DIMENSIONS

S-440 S-640 TOLERANCES

1

2

3

1

30

˝ (768.35 mm) 38

/

4

3

/

˝ (873.13 mm) 34

34

8

23˝ (584.2 mm) 23˝ (584.2 mm) +

1

˝ (971.55 mm) +

/

4

3

/

˝ (873.13 mm) +

8

1

1

˝ -

˝ (6.35mm)

/

/

4

4

1

1

/

/

˝ -

˝ (6.35mm)

4

4

1

1

˝ -

˝ (6.35mm)

/

/

4

4

2

3

b

1

1

5

d

1

2

4

1

6

3

b

a

8

c

7

BUILT-IN CUTOUT DIMENSIONS

S-440 S-640

1

2

3

4

5

6

DIMENSIONS

7

8

a

Note: For a countertop treatment: Recommended 3/4” (19.1 mm) overhang. Notch front edge for frame to fully slide in.

b

Gas Inlet

c

Side Burner Opening

d

Access for electric on left hand side

* Clearance from any surface or structure is at least 24” (609.6mm) from the back and sides of the grill or side burner.

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27” (685.8 mm) minimum distance from front edge of

®

24” minimum* (610 mm) 24” minimum* (610 mm)

3 3/4” (95.25 mm) 3 3/4” (95.25 mm)

6 1/4” (158.75 mm) 6 1/4” (158.75 mm)

10 1/2” (266.7 mm) minimum 10 1/2” (266.7 mm) minimum

23” (584.2 mm) 23” (584.2 mm)

34 3/8” (873.13 mm) 34 3/8” (873.13 mm)

the cutout for open lid clearance

30 1/4” (768.35 mm) Built-In Frame 38 1/4” (971.55 mm) Built-In Frame

27” (685.8 mm) minimum distance from front edge of

the cutout for open lid clearance

4

S-440

PARTS LIST

Lid - 1

Cookbox - 1

S-640

Lid - 1

Left Door - 1

Right Door - 1

Warming Rack - 1

OR

Right Enclosure Panel - 1

Cookbox - 1

Front Frame Rail - 1

Rear Frame Rail - 1

Rear Panel Assembly - 1

Left Enclosure Panel - 1

Front Vent Panel - 1

Rear Vent - 1

Bottom Shelf - 1

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PARTS LIST

5

Flavorizer® Bars

S-440

S-640

Stainless Steel Cooking Grates

S-440

S-640

Collection Tray - 1

Catch-Pan Holder - 1

Catch-Pan - 1

- 8

- 12

- 2

- 3

#10 Sheet Metal Screws - 5

5

Plastic Anchors - 5

1/2 inch Bolts (1/4 x 20 x 1/2 inch Bolt) - 8

#10-32 x 1/4 inch Steel Screws - 7

Nylon Washer - 8

1/2” Flare Gasket - 2

3/8” Flare Gasket - 2

Handle - 2

Disposable Drip Pans - 2

Hinge Pin- 2

Hair Pin Cotter- 2

Corrugated gas line - 1

Right Front Vent Clip - 1

Handle Hardware - 4

Rotisserie - 1

Rotisserie Fork - 4

Rotisserie Motor - 1

Rotisserie Bracket - 1

Keps Nuts (1/4 x 20 keps nut) - 2

1 inch Bolt (¼-20 x 1 inch Bolt) - 2

Left Front Vent Clip - 1

7/16 inch Wrench - 1

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Smoker - 1

Smoker Bar - 1

®

6

1

1

2

2

3

1

ASSEMBLY

Arrow stickers on
Frame Rail (1) and
Left Side Panel (2)
should point toward
each other (shown
above). Door Stop
Bracket (3) should
be positioned as
shown (left).

2

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3

 ATTENTION! Do not fully
tighten screws. Clips should
slide freely when installed.

ASSEMBLY

7

7

4

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8

5

ASSEMBLY

6

Back

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7

ASSEMBLY

9

9

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10

8

ASSEMBLY

 CAUTION: Use two people to lift and install the Summit® Built-In frame assembly.

A.) Lift the frame assembly into the “island” structure opening. Make sure the frame is resting level on the fi nished surface of the structure.
B.) Adjust the Front Vent to rest squarely on ground.

1

A.

1

1

1

b

a

1

1

a

B.

CLEARANCES

24" (610 mm) Any Surface

1

Grill Frame

a

Note: For a countertop treatment: Recommended 19.1 mm (3/4˝

b

inch) overhang. Notch front edge for frame to fully slide in.

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9

ASSEMBLY

11

11

1/4” (6.35 mm)
Drill Bit

10

S440

C.

(1)

C.) Apply a bead of silicone sealant

(1) around the perimeter and front

edges of the grill that are in contact
with the “island” structure. This
will prevent moisture seepage.
The sealant you use must have a
temperature rating above 120°F
(48.8° C).

S640

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12

ASSEMBLY

11

S440

F)'#

12

(1)

(2)

(3)

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ASSEMBLY

13

13

S640S440

13

14

(1)

S640S440

(2)

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15

ASSEMBLY

S640S440

Match Holder

a

b

c

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ASSEMBLY

15

15

1/4” (6.35 mm)
Drill Bit

17

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S640S440

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16

18

19

ASSEMBLY

S440 S640

S640S440

20

S640S440

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ASSEMBLY

17

21

S640S440

17

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18

22

ASSEMBLY

S-440

S-640

(1)

(2)

(3)

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+

+

+

23

AAA
AAA
AAA

S-440

S-640

a

ASSEMBLY

- 1

- 2

The Weber Grill Out™ Handle Light has a “Tilt Sensor”: Lid up - ON / Lid Closed - OFF. The power
button (a) activates or deactivates the “Tilt Sensor.” For daytime use, deactivate the sensor by
pressing power button (a).

S-440

S-640

19

19

- 2

- 4

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S-640

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20

GAS SUPPLY

BUILT-IN GAS LINE LOCATIONS

Note: Leave an access in the “island” structure for gas supply and regulator service that
is not inside the grill structure. Weber® has a gas line and regulator access door (part #

36311) available from your dealer or call Customer Service at 1-800-446-1071.

Note: Area should be kept clear of sharp, jagged, or extremely abrasive surfaces to avoid
possible damage to gas supply lines. Exercise caution when pulling gas lines through
built-in structure.

a

1

1

2

3

2

c

3

b

BUILT-IN GAS LINE LOCATIONS

SILVER GOLD TOLERANCES

1

2

DIMENSIONS

3

a

b

c

3 3/4˝

(95.3 mm)

6 1/4˝

(158.8 mm)

2 1/2˝

(63.5 mm)

3 3/4˝

(95.3 mm)

6 1/4˝

(158.8 mm)

2 1/2˝

(63.5 mm)

Plan View Left

Side View

Gas Inlet

+1/8˝(

- 1/8˝(

+1/8˝(

- 1/8˝(

+1/8˝(

- 1/8˝(

3.8

3.8

3.8

3.8

3.8

3.8

mm)
mm)

mm)
mm)

mm)
mm)

TYPICAL NATURAL GAS SUPPLY INSTALLATION

We recommend that this installation be done by a LICENSED professional.

GENERAL SPECIFICATIONS FOR PIPING

Note - Contact your local municipality for building codes regulating outdoor gas grill
installations. In absence of Local Codes, you must conform to the latest edition of
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.

• This grill is designed to operate at 4.5 inches (114.3 mm) of water column pressure.

• A manual shut-off valve must be installed outdoors, and be accessible, not in the
“built-in” structure. An additional manual shut-off valve indoors should be installed in
the branch fuel line in an accessible location near the supply line.

 CAUTION: If young children are in the area, a locking valve
should be considered.

• Pipe compound should be used which is resistant to the action of liquid propane
gas when gas connections are made.

• The gas connections must be fi rmly attached to a rigid, permanent construction.

Note: The information provided in this manual is general for typical installations. We
cannot cover all possible installation ideas. We recommend, prior to installation, that
you contact your municipality for local building codes and your local fi re department for
installation verifi cation.

If you have any questions, contact Customer Service at 1-800-446-1071.

GAS LINE PIPING

• Refer to the piping chart at the bottom of previous page.

• The corrugated gas line from the manifold is 58 inches (1,473.2 mm) long. Do not
extend the gas line.

• We have provided the means to make an SAE 45° fl are connection. Do not use
pipe sealant on this connection.

• If the length of line required does not exceed 50 feet, use a 5/8” O.D. tube. One
size larger should be used for lengths greater than 50 feet. Refer to piping chart.

• Gas piping may be copper tubing, type K or L; polyethylene plastic tube, with a
minimum wall thickness of .062 inch (1.57 mm); or standard weight (schedule 40)
steel or wrought iron pipe.

• Copper tubing must be tin-lined if the gas contains more than 0.3 grams of
hydrogen sulfi de per 100 cubic feet of gas.

• Plastic tubing is suitable only for outdoor, underground use.

• Gas piping in contact with earth, or any other material which may corrode the
piping, must be protected against corrosion in an approved manner.

• Underground piping must have a minimum of 18” cover.

Table

10-1

Nominal

Iron Pipe

Size

(Inches)

Maximum Capacity of Pipe in Cubic Feet of Gas per Hour for Gas Pressures of 0.5 psi or Less and a Pressure Drop of 0.3 Inch

Water Column. (Based on a 0.60 Specifi c Gravity Gas)

Internal

Length of Pipe (Feet)

Diameter

(Inches)

10 20 30 40 50 60 70 80 90 100 125 150 175 200

1/4 .364 32 22 18 15 14 12 11 11 10 98876

3/8 .493 72 49 40 34 30 27 25 23 22 21 18 17 15 14

1/2 .622 132 92 73 63 56 50 46 43 40 38 34 31 28 26

3/4 .824 278 190 152 130 115 105 96 90 84 79 72 64 59 55

1 1.049 520 350 285 245 215 195 180 170 160 150 130 120 110 100

1 1/4 1.380 1050 730 590 500 440 400 370 350 320 305 275 250 225 210

1/12 1.160 1600 1100 890 760 670 610 560 530 490 460 410 380 350 320

2 2.067 3050 2100 1650 1450 1270 1150 1050 990 930 870 780 710 650 610

2 1/2 2.469 4800 3300 2700 2300 2000 1850 1700 1600 1500 1400 1250 1130 1050 980

3 3.068 8500 5900 4700 4100 3600 3250 3000 2800 2600 2500 2200 2000 1850 1700

4 4.026 17500 12000 9700 8300 7400 6800 6200 5800 5400 5100 4500 4100 3800 3500

© 1997 National Fire Protection Association, Inc,. and International Approval Services - U.S., Inc. All Rights Reserved.

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GAS SUPPLY

21

TEST CONNECTIONS

All connections and joints must be thoroughly tested for leaks in accordance with local
codes and all listed procedures in the latest edition of 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.

 DANGER

Do not use an open fl ame to check for gas leaks. Be sure
there are no sparks or open fl ames in the area while you
check for gas leaks. This will result in a fi re or explosion
which can cause serious bodily injury or death, and damage
to property.

CONNECT GAS SUPPLY

A 58 inch (147.32 cm) corrugated gas line is supplied with the grill. This line needs to

pass through the gas inlet opening to the main gas supply.

1) Connect the corrugated gas line to the regulator (a). Use the 1/2” (12.7 mm) fl ared
gasket (1) to ensure proper seal.
(b) Shows the gas line and regulator assembled.

2) Uncap the fl are fi tting connection off the regulator.

3) Hard pipe the gas supply to the inlet of the regulator. Refer to “Typical Gas Supply
Installation”.

4) Connect the corrugated gas line to the manifold located on the right hand side of
grill under the control panel. Use the 1/2” (12.7 mm) fl ared gasket (1) to ensure
proper seal.

Note: Leave an access in the “island” structure for gas supply and regulator service not
inside the grill structure. Weber
available from your dealer or call Customer Service at 1-800-446-1071.

®

has a gas line and regulator access door (part # 36311)

21

1

2

CONNECTION CHART

1

Top View (Close-up)

2

Typical Natural Gas Pipe Routing

a.

Connecting Corrugated Gas Line to the Regulator

b.

Gas and Regulator Connected

c.

Hard piped gas supply

d.

Cap (Optional Side Burner)

e.

Corrugated Gas Line to Manifold

f.

Regulator

1

c.

1

c.

d.

f.

d.

f.

e.

(1)

a.

e.

b.

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22

GAS SUPPLY

VENTILATION

WARNING: Air holes must be provided in the structure at the
top and bottom to provide ventilation in the event of a gas leak.

Air holes can be located in a low visibility area and should be protected by screening
material to prevent rodents and insects from entering the structure. Air holes will also help
dry moisture.
Summit® Built-In cabinet vents are available from your dealer or call Customer Service at
1-800-446-1071.

Note: These drawings are only a reference.

• Cross ventilation must be incorporated in the supporting structure. We recommend
a minimum of 100 square inches (254 square cm )of venting per side.

• Vents should be on two sides of the structure.

• The above drawings are for reference only.

• Location of the vents should be from the center, outward.

• Locate the vents at both the bottom of the structure and at the top of the structure.

• The bottom vents should be as close to ground level as possible. Make sure the
vent area is not blocked by interior supports of the structure.

• We recommend vents with screens.

• Access doors to the structure are not considered vents.

• Clean the vents periodically.

 DANGER: Failure to follow recommended minimum venting
instructions can cause gas to collect in the structure in the
event of a gas leak. This may result in a fi re or an explosion
which can cause serious bodily injury or death, and damage to
property.

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23

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 ATTENTION: This product has been safety tested and is only certifi ed for use in a specifi c country. Refer to
country designation located on outer carton.

These parts may be gas carrying or gas burning components. Please contact Weber-Stephen Products Co., Customer Service Department for
genuine Weber-Stephen Products Co. replacement part(s) information.

 WARNING: Do not attempt to make any repair to gas carrying or gas burning components without contacting
Weber-Stephen Products Co., Customer Service Department. Your actions, if you fail to follow this product Warning,
may cause a fi re or an explosion resulting in serious personal injury or death and damage to property.

WEBER-STEPHEN PRODUCTS CO.

www.weber.com

©2007 The following trademarks are registered in the name of Weber-Stephen Products Co., an Illinois corporation, located at 200 East Daniels Road, Palatine, Illinois 60067 U.S.A.
Australia; Smokey Joe, Weber, Kettle Silhouette
tion, Botswana; Weber, Canada; Smokey Joe, Genesis, China; Kettle Silhouette
Smokey Joe, Weber, One-Touch, Germany; Smokey Joe, Weber, One-Touch, Greece; Smokey Joe, Ireland; Kettle Silhouette
Joe, Weber, Korea; Smokey Joe, Weber, New Zealand; Weber, Smokey Joe, Nigeria; Weber, Norway; Smokey Joe, Weber, Portugal; Weber, South Africa: Smokey Joe, Weber, Kettle
Confi guration, Spain; Smokey Joe, Weber, Sweden; Kettle Silhouette
One-Touch, U.S.A..; Kettle Confi guration, Kettle Silhouette
vorizer, Crossover, Flamgo, Performer, Rapidfi re, Tuck ‘N Carry, Jumbo Joe, Bar-B-Kettle, Master-Touch, Spirit, Grill Out, Summit, Platinum, 1-800-Grill-Out, Ranch, Matchless Flame,
Zimbabwe; Weber, Kettle Confi guration, Kettle Silhouette

, Genesis, Austria; Kettle Silhouette®, Smokey Joe, Weber, Benelux; Kettle Silhouette®, Smokey Joe, Weber, Compact Grill Confi gura-

, Denmark; Kettle Silhouette®, Smokey Joe, Weber, Finland; Smokey Joe, France; Kettle Silhouette®,

, Smokey Joe, Switzerland; Kettle Silhouette®, Smokey Joe, Weber, United Kingdom; Smokey Joe, Weber, Weber

, Smokey Joe, Weber, One-Touch, Firespice, Go-Anywhere, U.S.A.;Kettle Confi guration, Kettle Silhouette, Genesis, Fla-

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, Smokey Joe, Italy; Smokey Joe, Weber, Japan; Smokey