Char-Broil 8259778 Natural Gas Conversion Kit Instruction Manual

Char-Broil 8259778 Natural Gas Conversion Kit

Product Information

Natural Gas Conversion Kit for Char-Broil Modular Outdoor Kitchen Medallion Series Grills

The Natural Gas Conversion Kit is designed for use with Char-Broil Modular Outdoor Kitchen Medallion Series grills produced in 2018 or later with the Dual FuelTM logo. This kit allows users to convert their LP gas grill to a natural gas grill, providing a convenient and cost-effective grilling solution. The kit includes orifices, a hose, and a regulator required for the conversion.

Warnings and Cautions

• Connection to outdoor gas piping must be done by a certified plumber.
• Do not attempt to repair or alter this conversion kit for any assumed defect. Any modification to this assembly will void your warranty and create the risk of a gas leak and fire. Use only authorized replacement parts supplied by manufacturer.
• Do not store or use gasoline or other flammable liquids or vapors in the vicinity of this or any other appliance.

Prosuct Parts List

The kit includes:

• Natural Gas Orifices
• Natural Gas Hose
• Natural Gas Regulator

Product Usage Instructions

Please follow the below steps to convert your LP gas grill to a natural gas grill using the Char-Broil Natural Gas Conversion Kit:

Section 1: LP Gas Orifice Removal

1. Shut off gas supply to the grill.
2. Remove the grates and heat tents from the grill.
3. Remove the burners by unscrewing them from the control panel.
4. Locate the LP orifices on the burners and remove them with a wrench or pliers.
5. Replace the LP orifices with the included natural gas orifices for each burner.

Section 2: Control Knob Conversion

1. Remove the control knobs from the grill by pulling them off.
2. Remove the control knob bezels by unscrewing them from the control panel.
3. Remove the regulator from the control panel.
4. Install the new natural gas regulator onto the control panel in place of the old regulator.
5. Attach the included natural gas hose to the regulator and tighten with a wrench.
6. Replace the control knob bezels and knobs with the included natural gas versions.

Section 3: Hose and Regulator Conversion

1. Connect the other end of the natural gas hose to your home’s natural gas supply using a certified plumber.
2. Turn on the gas supply to the grill and check for leaks by applying soapy water to all connections. If bubbles appear, shut off the gas supply and tighten connections until bubbles stop.
3. Replace the burners, heat tents and grates onto the grill.
4. Light the grill and enjoy!

Please keep this manual for future reference and read all safety, assembly, and use and care instructions before using your new natural gas grill. If you have any questions or need assistance during assembly, please call 1-800-448-2177.

OUTDOOR MODULAR KITCHEN

3 AND 5 BURNER GRILLS

_ NOTE: _This kit is for use only with Char-Broil Modular Outdoor Kitchen Medallion Series grills produced from 2018 or newer, with Dual FuelTM logo, shown at right:

WARNING

This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction. If the information in these instructions is not followed exactly, a fire, explosion or production of carbon monoxide may result causing property damage, personal injury or loss of life. The qualified service agency is responsible for the proper installation of this kit. The installation is not proper and complete until the operation of the converted appliance is checked as specified in the manufacturer’s instructions supplied with the kit.

To Installer / Assembler: Leave these instructions with consumer.
To Consumer: Keep this manual for future reference.

Safety Symbols

The symbols and boxes shown below explain what each heading means. Read and follow all of the messages found throughout the manual.

• DANGER: Indicated 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: Indicated a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

DANGER

If you smell gas:

1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, keep away from the appliance and immediately call your gas supplier or your fire department.

If you have questions or need assistance during assembly, please call 1-800-448-2177

WARNING

Connection to outdoor gas piping must be done by a certified plumber.

Read and follow all Safety, Assembly, and Use and Care Instructions in this Guide before assembling and cooking with this grill. Failure to follow all instructions in this Use and Care Guide may lead to fire or explosion, which could result in property damage, personal injury or death.

Do not attempt to repair or alter this conversion kit for any assumed defect. Any modification to this assembly will void your warranty and create the risk of a gas leak and fire. Use only authorized replacement parts supplied by the manufacturer.

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 Tank not connected for use shall not be stored in the vicinity of this or any other appliance.

CALIFORNIA PROPOSITION 65

1. Combustion by-products produced when using this product contains chemicals known to the State of California to cause cancer, birth defects, and other reproductive harm.
2. This product contains chemicals, including lead and lead compounds, known to the State of California to cause cancer, birth defects or other reproductive harm. Wash your hands after handling this product.

CAUTION

Some parts may contain sharp edges, especially as noted in these instructions. Wear protective gloves if necessary. For residential use only. Do not use for commercial cooking.

• Installation must be made in accordance with any local codes or regulations, or in the absence of local codes or regulations, in accordance with the National Fuel Gas Code (NFPA 54/ANSI Z223.1).
• The hose and fittings are designed for movement after installation, but must not be kinked, twisted, or torqued.
• The hose and fittings should be visually inspected periodically to determine that they have not been damaged, and are suitable for continued use.
• Only use the quick connect socket with the plug end of provided hose.

USE & CARE

• Natural Gas Connections and Service Regulators Above 1/2 psi.
• Prior to 1998, all residential gas service regulators were set with an outlet pressure of 1/4 psi.
• In the 1998 edition of NFPA 54, the National Fuel Gas Code, a change was made allowing service regulators of 2 and 5 psi.
• With this change it was also required that an in line regulator be connected between the service regulator and the appliance regulator if the 2 or 5 psi system is used. This additional regulator is not supplied with this product.
• It is possible for a consumer, making the connection themselves, or a plumber, not checking, to tap into a 2 or 5 psi line. If a pressure of 2 psi or greater is supplied to the appliance regulator on certain grills it will shut down and not deliver any gas to the grill. The included quick disconnect socket and hose should not be used at pressures above 1/2 psi.
• If the quick disconnect socket, hose, and grill are properly connected and still not getting gas, delivery pressure needs to be verified. If pressure is greater than 1/2 psi, make sure that an in line regulator is present.
• Once the grill has been over-pressured, the regulator may or may not have been damaged. The best practice is to replace the regulator.

NOTE: If your home does not have an outside Natural Gas Supply, you will need a Certified plumber to install the Outside Gas Supply in accordance with any local codes or regulations, or in the absence of local codes or regulations, in accordance with the National Fuel Gas Code (NFPA 54/ANSI Z223.1).

WARNING

Do not use hard metal piping of any kind to connect this type of grill to outdoor gas connection. Use only hose specified by the manufacturer. Using hard metal piping or convoluted metal tubing is an unsafe practice. Movement of the grill can cause breakage of metal pipe.

CONVERSION OVERVIEW

• Remove cooking grate, if equipped, from the unit.
• Remove orifice from orifice holder.
• Replace with NG orifice from this kit.
• Reattach orifice holder to burner tube.
• Remove control knob(s).
• Install control knob NG stop pin(s).
• Replace control knob(s).
• Remove LP hose regulator.
• Assemble NG regulator bracket to NG Regulator
• Install NG Regulator and bracket to back panel of appliance.
• Reinstall cooking grate from the unit.
• Connect Gas Hose to Unit.
• Connect Gas Hose to Gas Source.
• Leak Check your appliance per your Appliance Product Guide.

TOOLS REQUIRED FOR ASSEMBLY

• Orifice Removal Tool – Provided
• 2 Adjustable Wrenches – Not Provided
• Flat Blade Screwdriver – Not Provided

Note: Illustrations are not to scale.

PARTS LIST

LP GAS ORIFICE REMOVAL

WARNING

• Place the grill on a flat, level surface before starting the conversion.
• This conversion kit shall be installed by a qualified service agency..
• Incorrect installation may result in explosion and serious injury.

Before starting the conversion, make sure all control knobs are in the OFF position, LP tank valve is closed and tank is disconnected from regulator and removed from unit.

NOTE: The grill shown is the three burner version. The assembly steps are the same for the five burner version.

• This completes Section 1: Before moving on to Section 2 – please reinstall your burner components in this order – Step 6, 5, 4, 3, 2, and 1.

CONTROL KNOB CONVERSION

NOTE: The control knob conversion procedure is the same for both the three-burner grill and the five burner grill.

1. Pull the burner control knob off of valve stem.
2. Using a Flat Blade Screwdriver, install the Control Knob Stop Pins into the location shown at below. Do not overtighten.
3. Reinstall your control knob(s) onto the valve stem. Be sure the knob is properly aligned before installation.

Section 2 is now complete. Please move on to Section 3.

HOSE AND REGULATOR CONVERSION

Overview of procedure

• Remove LP Regulator and Hose assembly.
• Install mounting bracket to Natural Gas Regulator.
• Install Natural Gas Regulator to inside back panel of appliance.
• Install Hose to Appliance.
• Install Hose to Gas Supply.

installation

• Section 4 is now complete. Please move on to Connection to Natural Gas Source.

IMPORTANT

Prior to installation, confirm with your local authorities having jurisdiction if any permits are required to comply with the state and local codes for natural gas installation. A certified or licensed gas technician shall be used to make all natural gas connections.

To allow proper heating performance of the grill, confirm that your home natural gas supply pressure is sufficient to maintain 4.0” W.C. Manifold pressure at the appliance (measured while it is in operation). A home natural gas supply pressure of 7”±1.5” W.C. entering the appliance regulator is desirable to achieve 4.0” W.C. outlet pressure at the appliance regulator. If the grill is operating at a gas pressure lower than 4.0” W.C., the resulting BTU rate for each will decrease resulting in poor heating performance. Decreased gas pressure can also make the appliance more susceptible to blow- out by wind. A certified gas technician can confirm if your home’s natural gas supply pressure is acceptable.

A certified gas technician will be able to determine the appropriate gas pipe size and length to connect your outdoor kitchen to your home gas supply.

IMPORTANT

• The conversion plate MUST be applied to the grill after the conversion process is complete and the grill has been tested successfully. Completely fill in the blanks indicated on the label:
  • Date the grill was converted.
  • Type of gas the grill was converted to use.
  • Model number of the conversion kit used to make the conversion.
  • Name of certified gas technician that performed the conversion, including company name and address.
  • Record the grill model number.
  • Record the BTU rating of the main and side burners.
• NOTE: Take care to write legibly and with a permanent pen / marker.
• Select a location on the grill large enough for the label to be applied.
  • We recommend that you apply the label as close to the grill’s certification label as possible.
• Do not apply the label around corners or edges of the grill sheet metal.
• You may be accessing areas of the grill that are not normally intended to be handled. Take care to avoid potential sharp edges, we recommend that you wear protective gloves.
• Clean the area of the grill in which the label will be applied with a degreasing detergent such as dishwashing liquid.
• Allow the area to dry.
• Carefully peel the backing off the label and apply the label to the grill.
• Press out any air bubbles, although the presence of air bubbles will not be an issue.

CONNECTING YOUR GRILL TO THE NATURAL GAS SOURCE

1. A professionally-installed shut-off valve between the supply piping and the socket is recommended, but not required, by the National Fuel Gas Code. Socket connection must be made outdoors.
2. Coat the gas supply pipe nipple with gas resistant pipe dope or approved teflon tape. Screw socket onto gas supply pipe (house gas source) as shown in Figure A below, and wrench-tighten.
   • CAUTION: The quick disconnect socket should never be connected to the grill. Direction of gas flow is indicated on the socket.
3. Pull back the sleeve on the quick disconnect socket and insert the unattached end of the gas hose into the socket. Release the sleeve and continue pushing the hose into the socket until the sleeve snaps into the locked position. See Figure B.
4. When the quick disconnect socket and the gas hose are connected, a valve in the socket opens automatically to permit full gas flow. When the gas hose is disconnected, the valve in the socket instantly and positively shuts off the flow of gas. Because the valve in the socket positively shuts off the flow of gas, the grill can be disconnected from the outdoor gas connection by disconnecting the gas hose from the quick disconnect socket. The socket should be left attached to the outdoor gas connection (house piping). Figure C shows properly connected hose and socket.

With proper assembly, the gas hose cannot be removed without pushing the quick disconnect sleeve back. To disconnect, push sleeve back and pull plug out of sleeve (this automatically shuts off gas).

Please Note: Hose and assembly are C.S.A. listed for natural gas, manufactured gas, mixed gas and for liquefied petroleum and for LP Gas-Air mixtures on basis of 0.64 specific gravity for 1000 BTU s per cubic foot of gas at 0.3 in. water column pressure drop. Only ANSI Z21.54 approved hoses should be used with this grill.

The appliance and its individual shut off valve must be disconnected from the outdoor gas connection piping system during any pressure testing on that system at test pressures in excess of 1/2 psig (3.5kPa). The appliance must be isolated from the outdoor gas connection piping system by closing its individual manual shutoff valve during any pressure testing of the outdoor gas connection piping system at test pressures equal to or less than 1/2 psi (3.5kPa).

TROUBLESHOOTING

EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.

• Damaged hose.

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• Turn off gas at at source. If anything but burned, replace parts. If burned, discontinue use of product until a plumber has investigated cause and corrections are made.

Troubleshooting

Burner(s) will not light using ignitor.

Burner(s) will not match light.

Sudden drop in gas flow or low flame.

Flames blow out.

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• No gas flow.
• Improper method of match-lighting.
• Natural gas valve not fully open.
• Out of NG gas or NG gas line obstruction.
• NG regulator lock-up
• High or gusting winds
• Low NG source line pressure or excessive NG source line pressure causing NG regulator lock up.

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• Make sure gas hose is properly connected to grill. If hose is properly connected, make sure gas source is turned on.
• Use long-stem match (fireplace match).
• See “Match-Lighting” section of Grill Use and Care.
• Open Natural Gas Valve to full open position.
• Check NG gas supply.
• Have plumber check NG gas supply pressure.
• Block the gusting winds
• Check NG gas supply. Check supply line run length and diameter. Source pressure > 5 in w.c. and < 1/2 psi.

©2020 Char-Broil, LLC. Columbus, GA, 31902. Printed in China.

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