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BBQ Grill Manual

1. M Erw SUN 4 Burner 34 SUN Infrared 4 Burner 34 SUN Infrared 5 Burner 42 Read all instructions before you operate your grill Save these instructions bali Conforms to ANSI k STD 21 582 2008 Pcs Seas For Residential Outdoor Use Only STD 1 6a 2008 To installer or person assembling grill Leave this manual with grill for future reference To consumer Keep this manual for future reference www sunstonegasgrills com Welcome amp Congratulations Congratulations on your purchase of a new grill We are very proud of our product and we are completely committed to providing you with the best service possible Your satisfaction is our 1 priority Please read this manual carefully to understand all the instructions about how to install operate and maintain for optimum performance and longevity We know you ll enjoy your new grill and thank you for choosing our product We hope you consider us for future purchases How to Obtain Service Before you call Is there Gas supplied to the Grill Is the battery inserted into igniter box Have you recently refilled the LP Tank Please make sure you have the following information Model Number Date of Purchase Serial Number The serial number can be located on the rating plate which is located on the right under side of grill above gas manifold pipe For warranty service contact SUNSTONE Customer Service Department at 888 934 9449 or
2. gt je rw a A T bons gt HEME at munt amt m up mE Dou estie jum 2 mm 58 irem 31 Rotisserie Hardware Group 5 Du uere rene pm ee 21s E i nu Ete Tm rs pass Part No Hood 3B Hood 3B H P TMeter P WR P GUBB P Lcover P IRburner P IIW P GSet3B P GMP P SAlvalve P Alvalve P Rsvalve P IIB P Knob S RB P Knob S P Knob L RB P Knob L P CP P Dtray P CPF P GBurner P FL 3B P FDivider P GBSF P LSB P RRSR P SMBox P LT P HAB P RHG P Rmotor P Rfork P RR P HRS NOTES Page 46 GRILL INSPECFICATION AND PARTS LIST SUN 4 Burner 34 Model Options NATURAL GAS SUN4B NG LIQUID PROPANE GAS LP SUN4B LP Material Specifications 304 Stainless Steel for Entire Structure 16 Gauge for External Hood Layer 20 Gauge for Internal Hood Layer 11 Gauge Cast Stainless Steel Burner 18 Gauge for Firebox 18 Gauge for Front Face Panel 18 Gauge for Drip Tray 20 Gauge for Flavor Systems Product Specifications Hood Closed Overall Width Overall Height Overall Depth Control Panel Height 11 1 8 Hood Open Size Counter to Top 26 1 4 Overall Depth Hood Overhang Burning Rating Up To 80 000 Btu Cooking Space 768 Sq Inch Electrical 60 Hz 15 amp circui
3. Gas Conversions Q Look inside opening and notice Infra Red T Back Burner Assembly Now that both top rack supports are flipped forward the top Three screws are all removed and the bottom back panel screws are all loosened you will now slightly lift up and wing entire back wall panel forward as wide open as possible m i 7 jor dede AN is bolted on 10 Loosen Flare Orifice Fastener using wrench pu PERS then remove with your hand and remove completley be careful not to drop fastener BY Slide Orfice and Flare assembly out of gas SPIDER AND se you con for easier handing INSECT WARNING Firmly Grasp Flare adapter with Right Hand while RE tuner CUNT INSECT WARNING Spiders and insects remove with hand be sure not to drop orifice can nest in the burners of this and other grills which could disrupt gas flow This dangerous condition could cause a fire behind and beneath the valve panel damaging the grill and making it unsafe to operate We recommend you check the grill and remove any spiders insects and webs at least once a year to reduce this risk Page 72 APPENDIX Knob amp Valve Adjustment Knob amp Ring Adjustment While turning any of the knobs and you notice any one sticking or rubbing Follow these steps 1 Turn each knob for any issues 2 For knob that rubs or sticks when either turned or pushed in remove knob and unscrew the four screws slightly so ring is lo
4. Gas companies for nearest certified LP dealers Page 19 GAS INSTALLATION amp MAINTENANCE Propane Tank Types LP Tank Exchange e Exchange your Type 1 cylinder with OPD safety feature equipped ONLY Always keep new and exchanged LP tanks in upright position during use transit or storage Leak e test new and exchanged LP tanks BEFORE connecting to grill Fig C Large Capacity Tank To House and Grill Dome Vapor Service Valve w Fixed Liquid Level Tube Liquid Level l Liquid Withdrawal Gauge Fill Valve Refief Valve with Check Loc Seal Welded stainless steel Lifting Lug 4 data plate under dome Float Flotteur Plugged Opening Cylinder Valve Medium Capacity Tank Handwheel Pressure Relief Valve Point of Connection Liquid Level Indicator Valve Guard Cylinder Tank Weld Page 20 GAS INSTALLATION amp MAINTENANCE Propane Tank Connection 42 Multi Sto Tank Tray Slide Out LP Gas Hook up This liquid propane grill is designed to operate on Liquid Propane ONLY The LP gas grill is designed to be used with a standard 20 lbs gas cylinder and must be constructed and marked in accordance with specifications of the US Department of Transportation for propane gas cylinders Always keep cylinder securely fastened in an upright position Never connect an unregulated propane gas cylinder to the grill Do not subject propane cylinders to
5. maintenance Tools and Parts Configuring Adapters Propane Tank Safety Propane Tank Types Propane Tank Connections LP Gas Line Connections Natural Gas Connections Grill Start up amp Safety Checks Pre operation Leak Test Pre Grilling Checklist Lighting the Grill Installing Components Rotisserie Installation Rotisserie Rod Assembly Side Burner Installation Transformer Installation Changing the Light Bulb Grill Specification and Parts list SUNG Burner 28 SUN Burner IR 28 SUN 4 Burner 34 SUN 4 Burner IR 34 SUN 5 Burner IR 42 Using Your Grill Types of Cooking Rotisserie Cooking Burner Configuration Burner Adjustments Grilling Tips Appendix Cleaning and maintenance Troubleshooting Gas Conversion Knob amp Valve Adjustment Warranty Read amp understand operators manual before using this Failure to follow operating instructions could result in death or serious injury ATTENTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate personal injury or property damage WARNING Indicates an imminently hazardous situation which if not avoided will result in death or serious injury VOLTAGE Indicates a potentially hazardous situation which if not avoided may result in minor or moderate electrical shock EXPLOSION Indicates an imminently hazardous situation which if not avoided will result in possible explosion and cause death or seriou
6. G AS START UP amp SAFETY CHECKS Pre Grilling Checklist v1 PRE GRILLING CHECKLIST Insert Battery Insert AA Battery into right side Igniter box Unscrew black cap counter clockwise be careful the external caps dm spring does not drop from its position Insert Battery with Male side facing out and tighten down igniter cap DO NOT FORCE THE CAP ON PAST THE TIGHTENED POSITION See Page 29 Maintain clearance to combustibles Your Sunstone grill performs well at HIGH temperatures and because of this it is especially important to keep combustible material away from grilling area by at least 24 inches Remember also not to store combustible items near or under the grill for risk of Fire Always keep adequate airflow into and out of island cabinet See Page 10 11 24 Clesrance OPEN POSITION Gas Supply Shut off Valve location It is important to know where your shut off valves are located If you ever have overheating or gas leaks this is an important safety issue Your shut off valve should always be in an area that is accessible if you already have one inside your island cabinet it is a good idea to have one outside as well See Page 23 26 GAS SUPPLY TO APPLIANCE LINE Knobs turn freely Since your ignition system works by pressing in your knob it is important to keep your knob in good working condition This is also important for turning the gas flow on and off and ke
7. Mix Solution DO NOT smoke while leak Prepare a leak testing testing Extinguish all open solution of soapy water by Ny flames Never leak test mixing in a spray bottle one with an open flame or risk part liquid soap to one part of serious harm to self or l water You can also use others mild detergent or liquid soap and water Leak Testing Procedure Perform a leak test at least once a year whether the gas supply cylinder has been disconnected or not In addition whenever the gas cylinder is connected to the regulator or whenever any part of the gas system is disconnected or replaced perform a leak test As a Safety precaution remember to always leak test your grill outdoors in a well ventilated area Never smoke or permit sources of ignition in the area while doing a leak test Do not use a flame such as a lighted match to test for leaks Use a solution of soapy water a Make sure all the control knobs are in the OFF position Bubbles b Turn on the gas i On natural gas systems turn the shut off valve to the grill ii On LP systems turn the propane tank valve knob counter clockwise one turn to open c Apply the leak testing solution by spraying it on joints of the gas delivery system Blowing bubbles in the soap solution indicates that a leak is present d Stopa leak by tightening the loose joint or by replacing the faulty part with a replacement part recommended by the manufacturer Do not atte
8. WHEN INSTALLING NEW LIGHTS as you may leave grease or dust on light bulb and can damage protective glass Locate Light Switch on Left side of Control Panel Be sure that when removing light bulb covers to place cover in safe place where they will not be chipped or harmed in any way Light Switch Part P LSB Page 39 INSTALLNG COMPONENTS Changing the Light Bulbs LIGHT REMOVAL AND REPLACEMENT 1 Remove the cover The light covers are supported a clip mechanism on the light fixture Simply cup the palm of your hand over the light cover from left or right sides and pry light cover off DO NOT USE ANY TOOLS as you might chip the tempered glass cover 2 Removing the bulb Reaching in using your fingers only grip the two outside edges of light bulb DO NOT grip the top or bottom of bulb as it might break Pull the bulb straight out so that the two electrodes wires are completely removed with bulb BE SURE TO PLACE BULB IN TRASH do not leave around were it could break and leave shards of glass 3 Installing new light bulb When handling your new bulb be sure to use a soft clean cloth cotton or paper towels Always keep halogen lights free of fingerprints and grease when operating Because the light bulb s very high operating temperature grease or fingerprints left on the bulb might reduce the bulb s life 4 Inserting bulb into position Insert the new light bulb using your c
9. air vent to top surface of island is 5 and the height from lower air vent to the bottom is 5 Island units must have vents cut into the island sides regardless of whether the grill is kept as NG or is converted to LP If no vent openings are made in the island unit the grill will overheat and cause a fire hazard If you have an L P model with a 20lb cylinder stored in the enclosure ensure that there at least two air ventilation openings of 20sq inches 180 degrees apart and they are level with the cylinder valve Another two openings with the same dimensions and distance are required to be level with the base of the cylinder e Do not use an extension cord to supply power to your island or appliance Such use may result in a fire Electrical shock or other personal injury e Do not install a fuse in the neutral or ground circuit A fuse in the neutral or ground circuit may result in an Electrical shock hazard e Use only Ground Fault Interrupter GFI protected circuit with this outdoor kitchen island e Keep all electrical components covered and secured away from any water or other liquids e Use only extension cords with a prong grounding plug rated for power of equipment and approved for outdoor use with a W A marking Page 7 NSTALLATION AND ASSEMBLY Island Safet Boo Wind blowing into or across the rear oven lid vent see fig B page 9 can cause poor performance and or dangerous overheating Orient the grill so that
10. cm minimum e Liquid Propane Supply Pressure 11 14 water column 27 9 35 5 cm not to exceed 14 water column and pressure 11 water column 27 0 cm minimum Note All BTU and water column requirements are approximations Page 13 GAS INSTALLATION amp MAINTENANCE Tools amp Parts Parts List Description Part No 1 Universal Gas Line Adapter P UGL 14 6 2 Safety Shut Off Valve P SSV 7 3 Male to Male Flare Adapter P MMA 8 4 Female to Male Flare P LPA 9 5 Four Way Connection P 4FA 10 11 Propane Gas Appliance Service Connections Recommended connections and Adaptors for Grill Installation Description Elbow Connection Adapter Three Way Connection Adapter Rubber Flex Hose Adapter NG Regulator LP Regulator and 21 Hose Gas Quick Connect 12 Hose Part No P 2FEA P 3FA P UGL 12 P NGRG P LPRG 21 P QCAH 12 Appliance service connections are the last line of delivery in a gas system Gas users are familiar with gas flex lines and fittings used to connect other appliances to an LP or NG Gas system and the proper connections must be made for these appliances to operate safely These appliance connections should be inspected by licensed service personnel such as an appliance technician or propane company representative Additionally propane or natural gas appliances must be connected to gas plumbing by way of a valve Appliances connected directly to building gas plumbing without a gas valve co
11. cubic feet per hour e NEVER use grill without leak testing ey For any adjustments to the LP Tank LP Tank Connection always turn the Grill Knobs to complete 1 The tank valve should be in the OFF position If not turn the knob clockwise until it ORE position Dee a ee LLL LLL stops 2 Make sure all burner valves are inthe OFF position 3 Always connect the gas supply regulator as LP Tank Disconnection follows Insert the regulator inlet into the tank valve and turn the coupling nut clockwise until 1 Turn the burner valves off the coupler tightens up see picture Do not 2 Turn the tank valve off Turn over tighten the coupler Turn the main tank clockwise to stop valve on and turn the burner control valves on 3 Detach the regulator assembly the unit to the HIGH position for about 20 from the tank valve by turning seconds to allow the air in the system to purge them quick coupling nut before attempting to light the burners Counterclockwise LP Propane Gas Supply Connection amp Disconnection CHECK HOSE FOR BREAKS OR WEAR BEFORE USE REGULATOR Page 18 GAS INSTALLATION amp MAINTENANCE Propane Tank Types Types of Propane Tanks Propane tanks are mainly used alongside stoves water heaters grills generators and welding equipment The
12. email service texasbbqwholesalers com we will response back within 24 hours Must keep copy of your sales slip for proof of purchase YOUR NAME DATE OF PURCHASE MODEL NO SERIAL NO l 1 1 1 1 1 1 ADDRESS 1 1 1 1 COMPANY THAT YOU PURCHASED FROM i 1 Unpacking and Assembly Your grill arrives nearly ready to use and requires little assembly Carefully follow these steps unpack the grill removing all packing material and protective film 1 Cut black plastic straps and lift grill from pallet WARNING Grill is very heavy you will need help and position grill near your island where the grill is being installed 2 Remove the green straps from around the grill box carton 3 Lift the cardboard box up and off be sure to tilt it back then turn it upside down so the Rotisserie Rod and any other packaging materials are retained in box It may require two people Or open top of box first and remove rotisserie rod and other packaging material 4 Remove the plastic wrap that protects the grill 5 Raise hood and unpack all parts 6 Cut plastic ties that hold the warming rack side shelves and spit rod 7 Remove warming rack at the back of grill by lifting up and sliding out 8 Remove rotisserie motor plus care and use manual 9 Reposition the warming rack at the back of the grill Page 2 INDEX DIRECTORY Installation Assembly Grill Safety Island Safety Locating Grill Cooking Zones Gas Installation amp
13. grill If there is excessive abrasion or wear or if the hose is cut it must be replaced prior to the outdoor cooking gas appliance being put into operation The replacement hose assembly shall be that specified by the manufacturer Ensure the area around the barbecue is clear of flammable substances such as gasoline yard debris wood etc Ensure there is no blockage of the airflow through the vent space located below the face of the unit 7 RS y OUTDOOR USE ONLY 1 DO NOT Store or use gasoline or NEVER operate grill in enclosed areas as this could lead other flammable liquids or to gas accumulating from a leak causing an explosion or vapors in the vicinity of this or a carbon monoxide buildup which could result in injury any other appliance or death DO NOT use your grill in garages breezeways 2 LP cylinder not connected sheds or any enclosed area NOT FOR USE BY CHILDREN for use shall not be stored in the If these instructions are ignored a hazardous fire or vicinity of this or any other explosion could result in physical injury death or appliance property damage Page 31 GAS START UP amp SAFETY CHECKS Lighting the Grill Lighting Instructions NS Open Lid Hood Ensure Burner Control Knobs igniter In the OFF position Turn on the gas supply valve Auto lgnition Knob Auto Ignition Safety Knob Infrared Back Burner Lighting 1 Push and Turn the last right knob 1 Push and Turn the I
14. keep clear of trees and shrubs 9 Donot build or place island under or near windows or vents that can be opened into your home e Maintain sufficient distance as to not overheat any overhead combustible material such as a patio cover e The area surrounding your island should be kept clean and free from flammable liquids and other combustible materials such as mops rags or brooms as well as solvents cleaning fluids and gasoline e Donotuse the island cabinet for storage of flammable or plastic items e Donotstore the liquid propane LP cylinder in the vicinity of the grill or other appliance when it is not being used e Donot block any island vent in such a way that will cause ventilation issue Fresh air must be able to pass through installed vents to safeguard against residual gas accumulation Aa wem Either for Modular or Built in island installation you MUST install proper air ventilation at the upper side and lower side of island face wall if adequate air ventilation is not installed risk of fire injury or explosion may result For Built in Installations Outdoor Kitchen Island should be built with NON Combustible applications including masonry stone or brick Never build deck below grill grill is supported by counter edge It is recommended that the enclosure have several ventilation holes or vents to prevent gas build up in the event of a leak See Fig A page 7 The deck ledges and counter should be flat and level in ref
15. poor combustion will result Location Locate the grill only in a well ventilated area Never locate the grill in a building garage breezeway shed or other such enclosed areas without an approved ventilation system During heavy use the grill will produce a lot of smoke Ensure there is adequate area for it to dissipate IMPORTANT Gas fittings regulator and installer supplied shut off valves must be easily accessible 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 223 1 1998 USA or CAN CGA B149 1 2 Natural Gas Propane Code Canada latest edition or the National Electrical Code ANSI NFPA No 70 or the Canadian Electrical Code CSA C22 1 1990 or latest version Page 8 INSTALLATION AND ASSEMBLY Locating Grill In FIG B Excess heat leaves through back of grill but is 5665 M Lib blocked by Prevailing Wind causing overheating of grill Fig A CORRECT WAY PREVAILING WIND 1 Slide Grill in Place Your Sunstone grill is specially designed with an internal built in hanger lip located at the Right Left and Back sides The grill lip allows it to hang by the three supported edges on the right left and back The front control panel requires no supporting edge it is designed to hang down the front of your cut out 2 Allow for Ventilation Your Sunstone grill is engineer
16. store a LP gas cylinder inside a building or in the vicinity of any gas burning appliance REGULATOR COUPLING NUT CYLINDER Page 22 GAS INSTALLATION amp MAINTENANCE LP Gas Line Connections This propane gas grill is designed to operate on propane gas ONLY at a pressure regulated at 11 water column W C when equipped with the correct propane orifices on the valves and a LP regulator on the supply line regulated at the residential meter For this type of propane installation the Propane Supply Tank is typically located in the side yard either above or below ground it is important to have a licensed plumber or installer do this installation since specific adjustments sometimes are required to the supply tanks pressure regulator Brecon For Large Capacity Propane tanks are typically located in your side yard and sometimes underground function with Propane Type Grills This type of gas installation can easily be mistaken for Natural Gas type since the installation method is similar to Natural Gas Be sure to confirm your gas type with an Licensed Plumber before proceeding 1 Safety Shut Off Valve should be Adjust hose to reach the 28 located in an accessible location length from LP Pipe i Connection to Grill Flare p Adapter For additional hoses and adpapters refer to page 14 P 4 To Grill 1 2 Flare Pe T cis u Quick Connect
17. to your home through pipes most of which run underground You may also have a secondary pressure regulator on an outside wall of your home to further adjust gas pressure A shut off valve in each pipe can be closed to stop gas flow to an individual appliance An appliance connector is the final segment in the gas piping system This specially designed flexible tube typically two or three feet long carries gas from a pipe to the back of an appliance Medium Capacity Tanks Any L P gas supply cylinder used with this grill must be approximately 12 inches diameter and 18 inches high The maximum fuel capacity is 8096 and is approximately 20 pounds of propane The L P cylinder must have a shut off valve terminating in a Type 1 L P A Type 1 compatible cylinder with a Type 1 cylinder valve has a back check valve which does not permit gas flow until a positive seal has been obtained LP Tank Filling e Use only licensed and experienced dealers e LP dealer must purged tank before filling e Dealer should NEVER fill LP tank more than 8096 of LP tank volume Volume of propane in tank will vary by temperature e A frosty regulator indicates gas overfill Immediately close LP tank valve and call local LP gas dealer for assistance e Donotrelease liquid propane LP gas into the atmosphere This is a hazardous practice To remove gas from LP tank contact an LP dealer or call a local fire department for assistance e Check the telephone directory under
18. w 12 Hose Single LP Quick Connect Regulator From Gas Supply To Grili Gas Supply Regulator To Gas Source 7 T Always take a leak test before lighting the grill to prevent a possible fire or explosion Never store a spare propane cylinder in the vicinity of this Grill or in the vicinity of any other potential heat source Never store a LP gas cylinder inside a building or in the vicinity of any gas burning appliance Page 23 GAS INSTALLATION amp MAINTENANCE LP Gas Line Connections 1 For this type of installation it is most similar to the NG gas installation method only the regulator is set for liquid propane First you will install a gas pipe coming into island from outside be sure the Safety Shut Off valve is easily accessible See Box 1 page 23 for illustrated parts Next locate the gas manifold on grill for this type of installation the 1 2 to 3 8 flare adapter and LP Regulator Hose that comes with your LP Grill is not needed Gas connections are made with all 1 2 flare adapters and UL Gas Hoses See page 14 for detailed lists of adapters and connections A LP REGULATOR is required for this type of installation even if the LP Tank is installed with one already LP regulator for grill should be set for a minimum of 120 000 BTU s with Medium Pressure This LP grill does not come with an independent LP regulator for this type of installation Contact the company you purchased from or you
19. with Natural Gas turn off gas supply at the system manual shut off valve DRIP TRAY The drip tray located below the grill should be cleaned periodically to prevent heavy buildup of debris NOTE Allow the drip tray to cool before attempting to clean IMPORTANT Do not leave the grill outside during inclement weather unless it is covered cover sold separately Rain water can collect inside the grill the grill cart or the drip tray if left uncovered If the drip tray is not cleaned after use and the grill is left uncovered the drip tray will fill with water causing grease and water to spill into the grill cart We recommend cleaning and storing the drip tray after every use WIPE IN THIS DIRECTION anion OR WITH THE GRAIN COOKING GRATES The cooking grates can be cleaned immediately after cooking is completed and after turning off the grill Wear a barbecue mitt and scrub the cooking grates with a damp cloth If the grill is allowed to cool down cleaning the grates will be easier if removed from the grill and cleaned with a mild detergent FLAVORIZORS WIPE IN THIS DIRECTION OR WITH THE GRAIN Washing the flavorizors after every use is not necessary but h A J periodically it is suggested you wash them in a soap and warm water solution Use a wire brush to remove stubborn burned on cooking residue Dry flavorizors amp flame dividers thoroughly before you reinstall them in the cooking insert Por
20. B 21 3 4 Openning Width For Sunstone Accessorry Doors and Drawers 10 7 8 Page 41 GRILL INSPECFICATION AND PARTS LIST SUN 3 Burner 28 Page 42 GRILL INSPECFICATION AND PARTS LIST SUN 3 Burner 28 SUN3B LP SUN3B NG Parts List No Description 1 Upper Hood saa N Grill Grates co Gas Manifold Pipe 13 Large Knob 14 Front Control Panel 19 Flame Divider 20 Grill Bottom Support Frame 25 Hood Rubber Stopper m Pin Pin N Part No Hood 3B Hood 3B H P TMeter P WR P GUBB P Lcover P GSet3B P GMP P Alvalve P Rsvalve P IIB P Knob L RB P Knob L P CP P Dtray P CPF P GBurner P FL 3B P FDivder P GBSF P LSB P SMBox P LT P HAB P HRS NOTES Page 43 GRILL INSPECFICATION AND PARTS LIST SUN Infrared 3 Burner 28 PRODUCT SPECIFICATIONS Model Options NATURAL GAS SUN3B IR NG LIQUID PROPANE GAS LP SUN3B IR LP a 26 Height Material Specifications EA T 304 Stainless Steel for Entire Structure 16 ke Gauge for External Hood Layer 20 Gauge for 28 Width Internal Hood Layer 11 Gauge Cast Stainless Steel Burner 18 Gauge for Firebox 18 Gauge for Front Face Panel 18 Gauge for Drip Tray 20 Gauge for Flavor Systems Product Specifications psi Hoo
21. GAS INSTALLATION amp MAINTENANCE Natural Gas Tank Connection E Adjust hose to reach m The Gas Safety Shut Off Valve should 8 ACape from grill to NG gas be in a easy to access location 3 connection Refer to i page 14 for additional connection options 1 2 Flare Adapter We recomend using the UL Quick Connect Hose adapter with it s 12 foot length it makes E connections easy T T Quick Connect Gas Supply TO GRILL SUPPLY REGULATOR Page 26 GAS START UP amp SAFETY CHECKS Pre Operation Leak Test DANGER 1 Do not insert any tool into the valve outlet or safety relief valve You may damage the valve and cause a leak Leaking propane may result in explosion fire severe personal injury or death 2 lfaleak is detected at any time or you cannot stop a gas leak immediately close pipeline valve and call LP gas supplier or you fire department 3 Check all gas supply fittings before each use and each time the gas supply cylinder is connected to the regulator Have a qualified service technician leak test the grill any time a part of the gas system is replaced B Always take a leak test before lighting the grill to prevent a possible fire or explosion Never store a spare propane cylinder in the vicinity of this Grill or in the vicinity of any other potential heat source Never attempt to attach this grill to the self contained LP gas system Do not use grill until leak testing ka N Before Testing 7
22. NE GAS LP SUN4B IR LP 26 Height Material Specifications Es EE CA 304 Stainless Steel for Entire Structure 16 tea 4 i Gauge for External Hood Layer 20 Gauge for 34 Width Internal Hood Layer 11 Gauge Cast Stainless Steel Burner 18 Gauge for Firebox 18 Gauge i for Front Face Panel 18 Gauge for Drip Tray 20 Gauge for Flavor Systems Product Specifications 26 1 4 Height Hood Closed z 26 Height Overall Width Overall Height Overall Depth 25 1 4 11 1 8 Control Panel Height 11 1 8 ana Hood Open Size 25 4 2 Depth az Counter to Top 26 1 4 25 1 4 Depth Overall Depth anes 1 INSTALLATION SPECIFICATIONS Hood Overhang Non Combustible Enclosure Burning Rating Up To 80 000 Btu IR Burning Rating Up To 20 000 Btu Cooking Space 768 Sq Inch Electrical 60 Hz 15 amp circuit110 120 V AC Power Cord 6 cord with grounded plug Product Weight 148 LBS Cut out Size 30 3 4 21 3 4 10 7 8 Openning Width For Sunstone Accessorry Doors and Drawers Page 50 GRILL INSPECFICATION AND PARTS LIST SUN Infrared 4 Burner 34 558 PRIUS Le Page 51 GRILL INSPECFICATION AND PARTS LIST SUN Infrared 4 Burner 34 SUNAB IR LP SUN4B IR NG Parts List NOTES No Description Qty Part No 1 Hood 4B 1 Hood 4B H I et I Eae I M S E o
23. ZONE The best location for your cleanup zone is as close to your sink as possible Items located near your cleanup zone will include not only items you ll use to clean up your outdoor kitchen and dishes below access storage and trash drawer for easy clean up COOKING ZONE For the best cooking zone location position it nearest to the triangle as possible either on one end or opposite of entertainment zone It s always best to give this area its own space so the chef can be more focused on cooking great food BEVERAGE ZONE The best location for your beverage zone is on one end of the island far away from your cooking zone but right next to your entertainment zone This makes it far more ease of use for your many guests STORAGE ZONE The best location for your storage zone is the either on one end of the island or right in the middle This zone should always be in an area that is easily accessible when multiple people are using the same space Page 12 GAS INSTALLATION amp MAINTENANCE Tools amp Parts Tools and Parts Gather the required tools and parts before starting installation Read and follow the instructions provided with any tools listed here Tools Needed 1 Tape Measure 0 2 Smallflatblade 3 Flatblade screwdriver 4 Wrench or pliers 7 Level 0 5 2and 3 Phillips screwdriver 8 Pipewrench 6 Scissors or cutting pliers 9 Noncorrosivelealctest LP Gas Mode
24. at from your foods to reduce the occurrence of flare ups during cooking 7 Applya light coating of cooking oil to the cooking grids before grilling to prevent foods from sticking 8 Cook similar portion sizes together so that they all cook evenly 9 Use tongs to turn foods on the Grill 10 Never pierce foods while they are cooking on the Grill as this will dry them out 11 Turn foods infrequently Some chefs say that a good steak should never be turned more than once 12 Apply sugar based sauces such as commercial barbecue sauces only during the latter stages of cooking to prevent charring 13 Soak the string you use to tie up roasts and poultry on the Rotisserie spit to protect it from burning 14 Use a disposable aluminum tray filled with water fruit juice wine or a marinade to add extra flavor and moisture to slow cooked foods like roasts whole chickens turkeys or ducks 15 Always cook foods adequately Undercooked foods can retain bacteria especially if thawed or exposed to warm conditions prior to cooking 16 Always use separate plates and utensils for the handling of raw food Never place raw food and cooked food on the same plate and never place cooked food on a plate that was used for handling raw food Page 62 USING YOUR GRILL Grilling Tips 17 Always carefully wash all plates and utensils used to handle raw food before using them to handle cooked food 18 Always use a meat thermometer to confirm that foo
25. ation 11 Unscrew each orifice one by one replacing with the correct gas type orifice Page 69 APPENDIX Gas Conversions Unfasten Screw Remove Left amp Right Screws Remove any wires Remove only the top from igniter and valves and bottom screws S ae 4 E T Locate the Orifice s for Za Use a wrench to each valve for replacement unscrew each Orifice __ Remove Valve and replace with New one Page 70 APPENDIX Gas Conversions The following instructions are required only for grills with Infra Red Back Burner Grills with this type of back burner come with the Rotisserie rod and motor It is necessary when converting your gas type to change the small orifice situated behind the thermal coupler and igniter in gas chamber of IR Burner Not changing this orifice will cause to much or not enough gas flow through and will be to hot or not hot enough depending on your gas type Using a Screw Driver unscrew and remove each screw Remove all SS Grates from grill cooking area It may be nessarry to loosen _ 1 back Screw Bolt bolts are located behind back of grill under back compartment Only loosen Screw head Do Not Remove after screws are loosened back panel will be able to be lifted up and swing forward Remove and flip the two Left and Right sides warming rack mounts forward rotating them on the opposite screw they are each mounted on APPENDIX
26. ay of wood chips will usually last about one hour During extended grilling chips may need to be added several times Lift the box only partially out of the grill to add chips while in use Never remove the hot smoker tray completely from the grill To improve smoke performance keep the hood closed as much as possible while food is grilling turn heat to Med Low setting with hood closed NOTE If not thoroughly soaked the wood chips will flare up during grilling To extinguish flames lift the smoker box slowly a few inches out of the grill front and add a small amount of water The smoker box can also be filled with water to produce steam which can help keep delicate foods moist during grilling TYPES OF WOOD CHIPS TO USE e Alder Medium tart smoke flavor Excellent on fish chicken or game e Maple Sweet hearty smoke flavor Best with fish jerky or bacon e Apple Light sweet smoke flavor Superb with poultry ham or sausage e Hickory Heavy smoke flavor Best with beef pork or game e Mesquite Light smoke flavor Excellent on fish poultry or beef e Oak Heavy smoke flavor Best with beef lamb or pork e Pecan Rich sweet versatile flavor Good with any grilled foods e Grapevine Strong smoke flavor Best with beef or poultry Page 63 APPENDIX Care and Maintenance A CAUTION All cleaning and maintenance should be done only when grill is cool amp with the fuel supply turned off at the cylinder If your grill is set up for use
27. configure a T Connection Adapter Kit as shown in A Consisting of a Safety Shut Off Valve Several Flare Adapters and two or more Universal Flex Lines you can also use a Quick Connect Hose which is especially useful if your connecting appliance is a further reach For natural gas anytime you are extending to another appliance it s always a good idea to install an additional regulator per appliance as shown in B Safety Shut Off Valve Side Burner Setup for Liquid Propane For Liquid Propane when installing an extra appliance like a side burner you will need to configure a T Connection Adapter Kit as shown in C Consisting of a Safety Shut Off Valve Several Flare Adapters one Universal Flex Line you can also use a Quick Connect Hose which is especially useful if your connecting appliance is a further reach Page 35 INSTALLNG COMPONENTS Side Burners Installation A Natural Gas Installation T Connection Configuration For Natural Gas installation when installing an extra appliance like a side burner you will need to configure a T Connection Adapter Kit as shown Consisting of a Safety Shut Off Valve Several Flare Adapters and two or more Universal Flex Lines you can also use a Quick Connect Hose which is especially useful if your connecting appliance is a further reach Extending from Safety Shut Off Valve is the Gas connection pipe Safety Precautions As a safety precaution install the provided NG re
28. cook with hood up when knobs are on HIGH HEAT setting NEVER close the hood and walk away Always turn burners to LOW HEAT when hood is in down position Grill Operation Do not use grill for other than intended use In the event that a burner goes out turn burner knobs to full OFF position fully open the grill hood and let any gasses out Do not attempt to use the grill until the gas has had time to dissipate Never use the grill if the drip pan is not properly installed Drip pan should be pushed all the way into the rack located just under the grill Fire or explosion can result from an improperly installed drip pan Keep all electrical supply cords and the rotisserie motor cord away from the heated areas of the grill Never use the grill or side burner in windy conditions If used in a consistently windy area a windbreak will be required Always adhere to the specified clearances listed in this manual Never allow clothing pot holders or other flammable materials come in contact with or be close to any grate burner or hot surface until it has fully cooled Never wear loose fitting or hanging garments while using your grill Fabric may ignite and result in personal injury Do not heat any unopened glass or metal container of food on the grill Pressure may build up and cause the container to burst possibly resulting in serious personal injury or damage to the grill Do not reach over your grill or any other surfaces when hot or in use Do
29. ction with the main burners of the grill If your grill does not come equipped with a specialized rotisserie burner you will use the main burners to create heat for the rotisserie When using the main burners for heat typically it is best to either turn the far Left and Right burners on only for true Convection style cooking When grilling rotisserie cooking large cuts of meat or extremely fatty meats place an aluminum foil pan with approximately 4 1 of water below the cooking grids and under the food Fig A page 59 The cooking grates are not required to be removed when cooking smaller meats The lower pan will serve to catch grease drippings which will prevent flare ups and also serves to provide moisture to the food being cooked Take care to fill up the pan with water while cooking as needed Always wait for the grill to cool completely before trying to remove the pan Note water can be substituted with wine beer juice or other liquids for enhanced flavor Please note it may be necessary to remove the cooking grids and flame directors as illustrated in Fig A page 59 from your grill in order to allow enough room for the rotisserie to properly rotate with the food Rest spit rod onto grooves in left and right side of grill head Allow the spit rod to rotate freely so that the heaviest part of the poultry meat is facing down Your Sunstone grill is included with a counterbalance set the counterbalance so that its weight is directl
30. d Closed Height Overall Width Overall Height Js Overall Depth 25 1 4 11 8 Height Control Panel Height 11 1 8 Hood Open Size I 25 1 4 Depth Counter to Top lt 27 Depth INSTALLATION SPECIFICATIONS Non Combustible Enclosure Overall Depth Hood Overhang Burning Rating Up To 60 000 Btu IR Burning Rating Up To 20 000 Btu Cooking Space 624 Sq Inch Bus q 21 3 4 Depth Electrical 60 Hz 15 amp circuit110 120 V AC Power Cord 6 cord with grounded plug _ A Product Weight 126 LBS Cut out Size 21 3 4 10 7 8 Openning Width For Sunstone Accessorry Doors and Drawers Page 44 GRILL INSPECFICATION AND PARTS LIST SUN Infrared 3 Burner 28 Page 45 GRILL INSPECFICATION AND PARTS LIST SUN Infrared 3 Burner 28 SUN3B IR LP SUN3B IR NG Parts List No Description Qty M TU EON od e gt un RE ess Nera em Ho UN ee T mercem us T Mund eee jum 7 IR Burner Back Burner 1 ECT tuna C 2 aa STIT ra SE he eer ee M ME Rar ent m a dus ma UESTRE E ANA ee 15 Small Knob Rubber Band 1 a eS we ae Reever es ma 2 2s uius on a E 1207 Duo Tos AC ae So ea ae a oe 23 Flavorizer 3 cae
31. d flame characteristic according to the procedure under Low Insufficient Heat Correctly installed burners should be seated firmly with no side to side movement Adjust the Air Venturi Bolt on right side of burner The bolt can be adjusted so more air flows into burner gas chamber for increased flame height Check the burner knob that it is correctly turning the grill valve and check to see if it is loose on valve Try pulling the knob directly off and manually turn the valve stem with your hand see if it turns gas flow on properly and ignition works If this works use a small flat head screw driver and very gently push it into the slip between the two pins at the tip of the valve stem This will slightly push the valve stem pins apart to create a stronger grip on control knob QUESTION See page 29 32 My Rotisserie burner will not light What should do ANSWER This is a tremendous safety feature on your Sunstone grills but it may cause some delays as grillers become familiar with the particular workings of these advanced safety valves The largest potential problem is in lighting the grill The safety valve requires heat at the rotisserie burner in order to send a signal to the valve to allow gas to flow to the burner What this means is that when lighting such rotisserie burners the griller must push in turn to HIGH and hold the rotisserie burner control knob until it reaches a sufficient temperature to hold the valve open This g
32. dle 5 Insert motor extension cord three prong plug into an adjacent grounded GFCI receptacle outlet 6 Before placing food item on forks when the rotisserie is being operated exclusively it is strongly recommended that a pan be placed on the grilling grids beneath the food to catch the meat drippings This will prevent excessive build up of drippings on the grids and facilitate cleaning When food item is placed on rotisserie be sure that all Bolts are tightened securely NOTE Close hood carefully and align Motor Bracket and Shaft Mounting Bracket so that Rotisserie Rod is in between the hood openings Lighting the rotisserie burner See Page 32 for Lighting Instructions 1 Grill surface burners should be off for rotisserie cooking Make sure Rotisserie motor is plugged in to GFCI outlet and turn it on Meat should be centered and balanced on the rotisserie spit rod for efficient cooking Use a drip pan under the meat to catch any juices Keep hood closed when cooking with the rotisserie EU erc Optional Rotisserie Rod Stow Away Locate two left and right notches at back of grill Locate two removable brackets and hook in place Un mount Rotisserie Rod from grill only removing the Forks and lift Rod over top and place in brackets INSTALLNG COMPONENTS Rotisserie Rod Assembly 1 Motor ya Forks Cem 2 Fast S m _ i Macr o4 o Bracket 1 Rod 1 Counter Weighte ROD i
33. ds have been fully cooked 19 Always wash all vegetables seafood and poultry before cooking 20 Always leave uncooked foods in the refrigerator until you are ready to start cooking 21 Always marinate meat in the refrigerator Dispose of the excess marinade and never reuse it 22 Always preheat your Grill for 2 to 5 minutes before cooking and clean off all grease and food residue before using the cooking grids 23 The US Department of Agriculture recommends the minimum temperature be reached for the following food items CROPS I 145 degrees F 62 8 C Ground Meat 160 degrees F 71 C l 160 degrees F 71 C Poultry 55 552 180 degrees F 82 C ROaStS eeeeee eee secco eei nee ru 145 degrees F 62 8 C Seafood erret 140 degrees F 60 C WOOD CHIP SMOKER By using real wood chips in the smoker box of your SUNSTONE grill you can add extra flavor to all of your grilled foods For good smoke performance soak the wood chips for not less than 30 minutes drain excess liquid and fill the smoker box completely HOW TO SMOKE e Fill the smoker box with thoroughly soaked and drained wood chips 9 Place the smoker box on the burner Replace the smoker box into the grill close the hood and set the smoker burner to high Smoke should begin in about 5 7 minutes One tr
34. e to Appliance 12 Min Clearance From A Appliance to Combustible Material 000 24 Min Clearance CUPIDE CELER Page 10 INSTALLATION AND ASSEMBLY Locating Grill COMBUSTABLE MATERIAL Height p 28 42 Product Width Overhead VentHood Line 25 39 1 2 Cut out Width d i 8 Min Distance 4 6 Min Vent Hood Clearance Sunstone Grill Product Outline Cut out line 21 3 4 Depth 27 Product Depth 4 6 4 6 Clearance zx 4 6 Clearance Clanes Non Combustible Wall Openning Width NON COMBUSTABLE MATERIAL y For Sunstone Accessorry Doors and Drawers Im o o 2 24 Clearance 12 Clearance F Page 11 INSTALLATION AND ASSEMBLY Cooking Zones ENTERTAINMENT ZONE The best location for your entertainment zone is on one end of the island far away from your cooking zone but right next to your beverage zone Make sure you have plenty of comfy chairs situated here SERVING ZONE The best location for your serving zone is in the center or heart of the island adjacent from the entertainment zone and easily accessible to all your many guests at once PREP ZONE The best location for your food preparation zone is the longest counter space that is near the sink and your grill top or near the ice chest one yt zo en CLEAN UP
35. ection flow limiting device is triggered mistakenly close the LP gas cylinder service valve and the burner valves wait 10 seconds to allow the device to reset open the cylinder service valve then open the burner valves and light the grill as per lighting instructions See page 9 13 60 61 QUESTION My grill is has Low Heat even when on High Setting ANSWER Ensure that adequate preheat time has elapsed I burners should preheat for at least 5 minutes with the hood closed 2 minutes for high heat IR burners should be allowed to preheat for at least five minutes with the hood open If adequate preheat time was allowed check the gas supply for a damaged and or kinked supply line Replace if necessary On LP units a mostly empty tank may not have sufficient pressure to run the grill at high heat Replace with a full tank Make sure that the regulator hose assembly being used is the unit supplied with the grill On NG units ensure that the flexible supply line is atleast 1 2 diameter Check the gas supply pressure to ensure at least 7 W C for NG and 11 W C for LP If gas supply is adequate check burners for blockages according to the procedure described above Check flame characteristics according to the procedure on page 61 and adjust air shutter if needed Check that there is no pressure being applied to the regulator attached to the back of the grill This regulator contains a flexible diaphragm and should not touch the grill body or any
36. ed with special vents on the back of unit which allow proper airflow out of the back of grill also increased airflow into Infra red Burner gas chamber Be sure you allow a minimum of 4 behind grill for proper air ventilation Slide grill all the way into cut out so there are no gaps present to inside of island frame 3 Securing in Place The control panel is designed to sit flush against the island face If counter top extends beyond the islands face creating a countertop overhang it must v gp EQ Cc 5 be cut flush with the island face where the width of 2 _ 5 the control panel or a gap will be created exposing the forward portions of the left and right side firewalls Also be sure to allow at least a 1 of clearance below grills drip pan for proper airflow ventilation Page 9 INSTALLATION AND ASSEMBLY Locating Grill M Ensure grill is installed with proper air flow for correct combustion air and cooling airflow Airflow MUST be maintained for the grill to perform as it was designed If airflow is blocked overheating will occur and poor combustion will result DO NOT INSTALL PLATFORM DIRECTLY UNDER GRILL Minimum Clearances When installing the grill in any area was an exterior wall or overhead structure is nearby pay close attention to the minimum distance requirements For installations with a wall behind grill it is especially important to allow enough room for adequate airflow or issues
37. en wing bolts Securely on meat forks Fig 4 Fig C USING YOUR GRILL Burner Configuration Grates Flavorizor Flame Director T Burner Igniter Preheating the Grill I BURNERS Preheating the grill is important for best performance To preheat the grill when cooking with the burners close the hood after lighting the burners as described above Set the grill control knobs on HIGH for 2 minutes or allow 5 minutes for a very high grill temperature Each grill burner is tested and adjusted at the factory prior to shipment however variations in the local gas supply elevation and other factors might make it necessary to adjust the burners Controlling Flare ups Flare ups are a part of cooking meats on a gas grill This adds to the unique flavor of cooking on a gas grill Excessive flare ups resulting from the build up of grease in the bottom of the grill can over cook the food and cause a dangerous situation for you and your grill If this should occur DO NOT pour water onto the flames which can cause the grease to splatter and could result in serious burns or bodily harm If grease fire occurs close the hood and turn off the main burners until the grease burns out Use caution when opening the hood as sudden flare ups may occur Fi B Meat Increases rises towards back of grill Burner Configuration Your Sunstone grill is engineered to perform with peak per
38. enerally will occur in approximately 5 seconds but in some Instances particularly in colder weather it may take longer You should follow the Lighting instructions to light the burner and ensure that the rotisserie burner is indeed lit before leaving the grill In addition to the safety valve described above there are a variety of other reasons that any burner will not light properly Page 67 APPENDIX Troubleshooting See page 60 61 QUESTION have excessive flare ups ANSWER Flare ups are typically caused when grease comes into direct contact with flames from the burner This often occurs when cooking particularly juicy foods or foods with sauces There are several ways to reduce flare ups Clean your grill often flare ups are caused by grease and residue that has built up on the inside of your grill A thorough cleaning of your grill will help to reduce these flare ups Use the indirect cooking method when cooking juicy saucy foods this technique recommends that you use the burners NOT directly below your food to create the heat necessary for cooking This means that there are no flames directly below your food for the grease sauce to contact and create a flare up For more information on indirect cooking see page 57 Turn down the heat some flare ups are caused simply because the grill is set at too high of a temperature for the food being cooked Turning down the heat to a medium or low setting may help to reduce some flare
39. eping a good knob to valve connection First with the gas flow in OFF position turn the knob ON OFF push in and release and check to see if knob is either rubbing Knob Ring or is difficult to turn See Page 73 GAS START UP amp SAFETY CHECKS Lighting the Grill WARNING When Lighting the Grill Hold the Knob in until Burner Ignites DO NOT RELEASE KNOB GAS WILL CONTINUE TO FLOW 1 Open Lid Before Lighting Burners 2 Make sure all Control Knobs are in OFF position 3 Push and Turn Last Right Knob to HIGH position 3 5 seconds to light burner 4 Ifignition does not occur in 5 seconds turn the last Right Knob to OFF wait 5 minutes to allow gas to dissipate and repeat the lighting process 5 To light the other burners push and turn knob one by one counterclockwise to HIGH position to allow gas to flow 6 To turn OFF turn each knob clockwise until it locks in OFF position Be sure to Push In to turn Knob A warnine Keep any electrical supply cords and the fuel supply hose away from any heated surfaces Failure to open the lid while igniting the barbecue s burners or not waiting 5 minutes to allow the gas to clear if the barbecue does not light may result in an explosive flame up which can cause serious bodily injury or death r O Never stand with your head directly over the Grill when preparing to light the Rotisserie burner to prevent possible bodily injury Inspect the hose before using the
40. epth 27 Depth gt INSTALLATION SPECIFICATIONS Non Combustible Enclosure Openning Width For Sunstone Accessorry Doors and Drawers Page 53 GRILL INSPECFICATION AND PARTS LIST SUN Infrared 5 Burner 42 Page 54 GRILL INSPECFICATION AND PARTS LIST SUN Infrared 5 Burner 42 SUNSB IR LP SUN5B IR NG Parts List No Description Qty Part No Upper Hood m e N Hood Rubber Stopper NOTES Page 55 USING YOUR GRILL Types of Cooking Cooking Zones Your Sunstone Grill is divided into three to five individual cooking zones depending on the number of burners you have Burners are numbered starting at one 1 on the right going to as much as five 5 on the left and the last cooking zone is above for either the warming rack or rotisserie unit Each cooking zone is designed to be controlled individually by the burner control knob Specific zones are better suited to specific types cooking Heat Distribution The heat level at each part of the grill has been engineered for specific purposes Knowing the heat distribution for each burner will allow you the very best possible food positioning when grilling The front of the grill is designed for safety reasons to be the coolest part of the grill From the front of the grill and moving back the heat rises gradually until
41. er installation or installation not in accordance with the instructions contained in the User Manual or the local codes 4 SUNSTONE shall not be liable for incidental consequential special or contingent damages resulting from its breach of this written warranty or any implied warranty 5 Some states do not allow limitations on how long an implied warranty lasts or the exclusions of or limitations on Consequential damages This warranty gives you specific legal rights and you may have other rights which vary from state to state 6 Noone has the authority to add to or vary SUNSTONE warranty or to create for SUNSTONE any other obligation or liability in connection with the sale or use of its products WHAT IS NOT COVERED amp INTERNET PURCHASE DISCLAIMER 1 SUNSTONE shall not be responsible for and shall not pay for the following Installation or start up 2 Service by an unauthorized service provider 3 Damage or repair due to service by an unauthorized service provider or use of unauthorized parts 4 Damage caused by accidents abuse alteration misuse installation that is not in accordance with the instructions contained in the User Manual or local codes 5 Tocorrect normal adjustments or settings due to improper installation commissioning or local gas supply properties 6 Shipping and handling costs export duties or installation cost 7 The cost of service calls to diagnose trouble or Removal or re installation cost T
42. erence to the floor If your grill is equipped with a rotisserie or lights electrical service should be provided GFCI electrical plugs are required for outdoor use If your grill is equipped with a rotisserie a minimum of 24 609 6mm of clearance is needed on each side of the grill for the motor and skewer For Modular Installations Outdoor Kitchen Island should be built with Non Combustible applications including Steel Welded Frame or Steel Stud Frame finished with Cement Board For modular installations a moisture barrier is recommended using pressure treated composite board under base of island Interior should be lined with ABS plastic liner as additional protection No deck below grill is required grill is supported by counter edge It is recommended that the enclosure have several ventilation holes or vents to prevent gas build up in the event of a leak See Fig A page 7 The deck ledges and counter should be flat and level in reference to the floor If your grill is equipped with a rotisserie or lights electrical service should be provided GFCI electrical plugs are required for outdoor use If your grill is equipped with a rotisserie a minimum of 24 609 6mm of clearance is needed on each side of the grill for the motor and skewer Page 6 INSTALLATION AND ASSEMBLY Island Safet AN srrention Upper and lower air vents 20 sq in minimum each MUST BE PROVIDED on both sides of built in construction The height from upper
43. esults i 1 A4 ore 1 MI ay 1 RE Indirect Cooking Indirect cooking is the process of cooking your food without the heat source directly under your food You can sear meats over a high flame on one side of the grill while slow cooking on the other side of the grill It is like cooking in a oven and is generally used for larger cuts of meats but can also be used for cooking foods that are prone to flare ups Indirect Cooking will result in tender foods every time you grill BE SURE TO REMOVE FLAME DIRECTORS FOR HEAT TO PROPERLY FLOW Sear Cooking Sear cooking is the process of cooking your food directly on top of burner on HIGH heat It is best associated with Searing your food with High Heat Sear cooking is recommended for most grilling applications and the best reae ee s 44014 aia place to sear is in the back of burner Searing locks in CINE COR TL flavor and juices while allowing the outer surface to WEIT il absorb smoke and food aroma that is produced AT IM as grease and drippings are vaporized by the burner The HH result is a crisp flavorful outside with a tender juicy inside see Page 60 Fig B USING YOUR GRILL Rotisserie Cooking The first step is to identify if your grill includes a specialized rotisserie burner or not If your grill does include a rotisserie burner make sure to use only the IR burner DO NOT use it in conjun
44. excessive heat aco It is recommended you use a Propane Tank Pull Out Drawer It is severely hazardous to move propane tanks in and out of Island enclosure without assistance of drawer See below for Sunstone s Combo Tank Tray Pull Out Drawers available 32 Premium Multi Storage Tank Tray Side Out 32 Multi Storage Tank Tray Slide Out B item No A LPCDD42 item No C LPDC ltem No A LPDC Page 21 G AS INSTALLATION amp MAINTENANCE Propane Tank Connection LP Hose Regulator and 1 2 to 3 8 Flare are provided with grill For LP Grills Flare Adapter is Pre Installed 1 2 to 3 8 Flare 1 2 Flare 1 Gas Manifold DO NOT USE TEFLON PIPE SEAL ON ANY Identify Connections and adapters The 1 2 to BRASS FITTINGS OR FLARE ADAPTERS 3 8 flare adapter is pre installed for LP Grills Secure all connections with a wrench then leak Gas hook up is on right side of grill test refer to page 28 Locate LP regulator and adjust hose to wi m reach the length from LP tank to grill If the reach is to far refer to page 14 for additional connection options ES Regulator is Pressure Sealed screw tightly on clockwise A warnine Always do a leak test before lighting the grill to prevent a possible fire or explosion Never store a spare propane cylinder in the vicinity of this Grill or in the vicinity of any other potential heat source Never
45. formance and allowing you to have Searing temperatures in any burner location With a Fully Enclosed Firebox and Flame Directors that help to insure all heat is Directed Upward with very little heat loss Venturi Bolt Burner Balance Adjuster Page 60 USING YOUR GRILL Burner Adjustments Correct Flame Color and Height Flames should be blue and stable with no yellow tips excessive noise or lifting If any of these conditions exist check if the air shutter or burner ports are blocked by dirt debris or spider webs If needed proceed with air shutter adjustment The amount of air which enters a burner is governed by an adjustable bolt at the inlet called an air shutter It is locked in place by a set screw which must be loosened prior to lighting the burner for adjustment Flames should be blue and stable with no yellow tips Excessive noise or lifting Combustion Chamber Balance The bolt on the Right side of each burner called is called the AIR VENTURI andit regulates the amount of air that enters into the burner for combustion The air venturi adjustment screw are accessible by using your hand be sure burner is not hot e the flame is yellow indicating insufficient air turn the air venturi bolt counterclockwise to allow more air to the burner e the flame is noisy and tends to lift away from the burner indicating too much air turn the air venturi bolt clockwise Burner Balance Adjustment Sunstone
46. g eres TIU ee eeu I IR eese a e psn o m ps DE ECE E P Knob L RB P Knob L P CP P Dtray P CPF P GBurner P FL 4B P FDivder P GBSF P LSB P RRSR P SMBox P LT P HAB P RHG P Rmotor P Rfork P RR P HRS N 35 Hood Rubber Stopper Page 52 GRILL INSPECFICATION AND PARTS LIST SUN Infrared 5 Burner 42 Model Options NATURAL GAS SUNSB IR NG LIQUID PROPANE GAS LP SUNSB IR LP Material Specifications 304 Stainless Steel for Entire Structure 16 Gauge for External Hood Layer 20 Gauge for Internal Hood Layer 11 Gauge Cast Stainless Steel Burner 18 Gauge for Firebox 18 Gauge for Front Face Panel 18 Gauge for Drip Tray 20 Gauge for Flavor Systems Product Specifications Hood Closed Overall Width Overall Height Overall Depth Control Panel Height 11 1 8 Hood Open Size Counter to Top 26 1 4 Overall Depth Hood Overhang Burning Rating Up To 100 000 Btu IR Burning Rating Up To 20 000 Btu Cooking Space 960 Sq Inch Electrical 60 Hz 15 amp circuit110 120 V AC Power Cord 6 cord with grounded plug Product Weight 177 LBS Cut out Size 39 1 2 10 7 8 PRODUCT SPECIFICATIONS 26 A k Height EA AAA vw i f t 42 Width i 26 1 4 Height 26 Height T e 11 1 T EZ 23 1 2 Depth e 25 1 4 D
47. grills are specially designed with Burner Balance Adjustment Bolts in order to fine tune your cooking experience For minor changes to the burner overall performance and achieving the perfect amount of Air and Gas mixture e Remove Drip Pan and peer under grill front control panel to view the underside of grill structure See the burner Balance Bolt e Adjust bolt using a wrench either clockwise or counter clockwise Burner Removal For general cleaning or other maintenance you can remove the burner by removing the burner bolt nut It is a good idea to clean your burners if you are not achieving the desired results Insects dust or other debris could be blocking proper Air and Gas flow to Burner e Locate the bolt from underneath the grill in the far back behind the grill box wall You will be required to use a wrench to adjust this bolt e Remove the bolt nut and remove the burner from grill for closer inspection Figure 1 1 MAXIMUM A 3 8 MAXIMUM Y Page 61 USING YOUR GRILL Grilling Tips A warnine Always observe safe food handling and safe food preparation practices when using this Grill to prevent food borne illnesses General Temperature Settings High Intended for fast pre heating of the appliance searing steaks and other cuts of meat rotisserie cooking and for burning food residue from the interior of the appliance Medium For most grilling baking and roasting Lo
48. gulator for each additional appliance you have Whenever extending gas through long hoses gas pressure can change depending on the length and size of hose Also always use an additional safety shut off valve or quick connect hose between appliances for quick gas shut off if hazard arises Liquid Propane Installation T Connection Configuration For Liquid Propane installation when installing an extra appliance like a side burner you will need to configure a T Connection Adapter Kit as shown Consisting of a Safety Shut Off Valve Several Flare Adapters and two or more Universal Flex Lines you can also use a Quick Connect Hose which is especially useful if your connecting appliance is a further reach Extending from Safety Shut Off Valve is the Propane tank Dual Propane Tank Setup When using an additional appliance like a side burner with liquid propane many customers prefer to modify their installation for Dual Propane Tanks Configure a Double T Connection each propane tank is required to have its own safety shut off valve for interchanging multiple tanks at once This is to be used as an informational purpose only UL Flex Hose 1 2 Flare KHA Elbow Adapter 1 2 Flare Safety Shut Off Valve Safety Shut Off Valve iow be Regulator UL Flex Hose T UL Quick Connect Gas Hose T Adapter and 1 2 flare adapters Propane Tank 1 LP Hose Regulator Propa
49. his warranty applies to the original purchaser with invoice or proof of purchase and covers Sun products intended for personal family or household usage only It does not apply to rust corrosion oxidation or discoloration which may occur due to moisture or overheating unless the affected component becomes inoperable This warranty does not cover parts becoming defective by misuse accidental damage improper handling and or installation It does not cover labor or labor related charges It specifically excludes liability for indirect incidental or consequential damages Some states do not allow the exclusion or limitation of incidental or consequential damages so the above exclusion or limitation may not apply to you This warranty gives you specified legal rights and you may have other rights which may vary from state to state For additional information regarding this warranty or information on how to place a warranty claim contact your authorized Sun dealer or Texas BBQ Wholesalers Page 74
50. just above the burner s jet TE et front edge where it rises rapidly to a medium to high op fed UN We m SAY temperature The heat continues to rise to searing heat p sed III fi hire Men si amount towards the back of grill burners M INE Emi Flame Directors Your Sunstone Grill is designed for an exquisite cooking experience with the use of flame directors which are wall dividers that fit between each burner compartment The flame directors help to insulate each cooking zone to give maximum heat isolation so that you are able to achieve separate heat zones with very little impact on other zones used for low heat cooking while others for high heat searing Simply lift grate up and pull divider up and out of position You can customize your cooking experience to your own preference and zone configuration either large or small Meas mo A Ya Page 56 USING YOUR GRILL Types of Cooking Smoker Steamer Box Adding the smoker box to your cooking experience adds unique flavor to your food you will come to enjoy Use it for either a smoker box with wood chips or bv filling with Water it becomes a steamer box While in use remember to close the hood with the knobs set to LOW for maximum results There are many different wood chips available on the market the most common are mesquite andhickory Just remember to soak the chips for 30 minutes prior for best r
51. lean cloth in hand very little effort is required for the bulb to SNAP and lock in place Look at the bulb and verify that no fingerprints are left on it Wipe off any fingerprints and or grease that might have accidentally come in contact with glass of the light bulb CHECK ALL LIGHTS WIRES AND CONNECTION THEN FLIP THE SWITH ON Page 40 GRILL INSPECFICATION AND PARTS LIST SUN 3 Burner 28 PRODUCT SPECIFICATIONS Model Options NATURAL GAS SUN3B NG b LIQUID PROPANE GAS LP SUNS3B LP 26 Height Material Specifications gt 304 Stainless Steel for Entire Structure 16 ge Gauge for External Hood Layer 20 Gauge for _ i Internal Hood Layer 11 Gauge Cast Stainless Width A Steel Burner 18 Gauge for Firebox 18 Gauge for Front Face Panel 18 Gauge for Drip Tray a 20 Gauge for Flavor Systems 26 1 4 Product Specifications Height 26 Hood Closed Height Overall Width i 2 Dan Overall Height Overall Depth 2 Lip Control Panel Height 11 1 8 Hood Open Size 23 1 2 Depth Counter to Top 26 1 4 a E 27 Depth Overall Depth Hood Overhang 25 Width Burning Rating Up To 60 000 Btu Cooking Space 624 Sq Inch Electrical 60 Hz 15 amp circuit110 120 V AC Power Cord 6 cord with grounded plug Product Weight 116 LBS Cut out Size 10 7 8 Height E
52. ls NG Gas Models Parts Needed Parts Needed 1 20 LP gas fuel tank approximately 18 1 Gasline shutoff valve long hose 45 7 cm Height and 12 30 5 cm diameter 2 Gas resistant pipe joint compound 3 CSA design certified outdoor flexible stainless Steel appliance Connector Parts supplied Parts supplied 1 LP Regulator with 21 Hose 1 NG Regulator 2 Flare Adaptor 2 4 9 hose Gas Pipe Requirements e pressure regulator must be installed on all gas equipment All local codes require that a pressure regulator be installed Removing or failing to install the pressure regulator can result in fire and serious bodily harm e Aninstaller supplied gas shut off valve must be installed in an easily accessible location for all hard plumbed natural gas and liquid propane applications e In order for a Sunstone Grill to perform properly you must have adequate gas plumbing Please see the guidelines below to help ensure that you have the appropriate gas plumbing with respect to gas pipe diameter length of pipe run and the grills BTU requirements Natural Gas Pipe Size Chart Pipe Size 10 FT 20 FT 30 FT 40 FT 50 FT 60 FT 1 2 170 000 118 000 95 000 BTU 80 000 BTU 71 000 BTU 64 000 BTU 3 4 360 000 245 000 198 000 169 000 150 000 135 000 BTU Water Column Requirements e Natural Gas Supply pressure 7 water column 17 8 cm min and pressure under full load 4 water column 10 2
53. may occur For islands that are built using combustible materials you must not surround same materials around any appliance or risk fire You MUST use Non Combustible building materials within 24 around all sides of appliance ie Stone blocks steel studs Never locate the grill where the exhaust will be difficult to clean If you wish to use the rotisserie option the space is essential for motor and skewer clearance Minimum Requirements TOP VIEW See Diagram Page 11 to Right From Appliance to Combustible Material 24 Min Clearance a This grill MUST NOT be located in any fully enclosed area of any kind There should be a minimum of 4 6 feet clearance from the top hood of grill and any overhead combustible structure Vent Hood Exhaust If installed or used under a patio roof the cooking grid area must be fully covered by an exhaust hood with a vent An exhaust fan with a rating of a minimum 1 000 CFM cubic feet per minute 472 liters per second or more may be necessary to effectively remove smoke and other cooking by products from the area under the unprotected overhead combustible construction Minimum Requirements FRONT VIEW See Diagram Page 11 toRight n 1 From Counter to Overhead Structure 8 ft Min Clearance From Counter to Outdoor Vent Hood 36 Min Clearance From Floor to Counter Top 88 Min Clearance MEM From Grill to Vent Hood Width Paso Min Clearance From Applianc
54. mpt to repair the cylinder valve if it is damaged The cylinder must be replaced e Turn all control knobs back to the full OFF position Page 27 GAS START UP amp SAFETY CHECKS Pre Operation Leak Test Liquid Propane Leak Testing Procedure Test connection from LP Tank to Regulator Test connection from grill to LP Hose Natural Gas Leak Testing Procedure If unable to stop gas leak turn gas off Test connection next to NG regulator p Test connection from gas line to adapter Test Quick Disconnect Page 28 GAS START UP amp SAFETY CHECKS Pre Grilling Checklist Start Up Before you start cooking clean the entire grill thoroughly with hot soapy water This is necessary to remove residual solvents oil and grease used you can also Burn OFF any heavy solvents by closing hood and heating grill up to High temperature for 2 5 minutes Safety Checks 1 Check the battery that it is free from defect and functions properly 2 Turn each knob make sure each one rotates easily does not stick and is free from defect 3 Checkthe spark igniters next to burner make sure they are free from debris with proper spacing from burner so adequate ignition is performed 4 For Grills with a IR back burner check the igniter that it has proper spacing and functions properly Electrical S i to Ifhition Syste n ayout For IR Grills Both Ignition Knobs work on a Loop Page 29
55. n Left side of grill control panel The Transformer s electrical connection to grill is located behind control panel next to light switch The connection clips together to form a secure connection Double check that all wires are tightly pushed into plug sockets so all wires make proper connections You can tuck wire into body of grill or island frame so it s up and out of the way 3 Install the Ground Wire The short green wire extending from off the transformer electrical adapter is required to be grounded Depending on the location you decide to install transformer it may be necessary to extend the wire so that it can reach a grounding structure A grounding structure is any solid structure that makes direct contact with the ground Transformer 4 t Connector to Grill Side Mount on Cabinet Wall 8 p Snap Clip Connection Plug To Transformer Ground Connection Yy Electrical Line amp Grounder INSTALLNG COMPONENTS Changing the Light Bulbs A warnine Never attempt to replace light bulb when grill is in use Serious Burn will result Never touch halogen bulbs with your bare fingers Use a tissue or a small piece of paper to handle bulbs Oils from your hands will damage halogen bulbs Changing the Light Bulbs Locate the two Lights at the back of grill enclosure Then follow steps 1 thru 4 to safely remove light bulbs and install new working ones DO NOT USE BARE HAND
56. ne Tank 2 UL Flex Hose Grill Side T Adapter Burner UL Quick Connect Gas Hose Page 36 INSTALLNG COMPONENTS Transformer Installation Installing the Transformer All grills with electrical components such as lights will require the transformer to be installed and plugged in before you can use it This needs to be done before the grill is inserted in the island When the transformer is attached to the island frame cabinet inner wall use care in placing the grill in the island cutout to avoid hitting the transformer or rubbing electrical wires Right Light Left Light Grill Shown with Back Removed GFCI Plug Electrical Connection Wi Plug 3 Prong Plug Light Switch ON Transformer Electricalal Box Grounding Wire Page 37 INSTALLNG COMPONENTS Transformer Installation 1 Locate the transformer Remove the transformer from the plastic bag located in the interior of grill Make sure the Transformer is complete and double check the grill light plug cord is properly secured to transformer and all wires are firmly fixed into plastic clip plug 2 Mount Transformer Using metal screws and attach the transformer to the back inner wall of your islands cabinet wall somewhere near the already installed GFCI electrical outlet When you plug the transformer in double check then GFCI breaker switch that the outlet has power 4 Make Connections Locate the Light Switch o
57. nfrared back burner Auto Ignition Knob to HIGH position 3 5 knob Auto Ignition Safety Knob to HIGH seconds to light burner position 3 5 seconds to light back burner Main Burner Lighting 2 If Ignition does not occur in 5 seconds 2 If Ignition does not occur in 5 seconds turn the last right knob to OFF wait 5 turn the back burner control knob to minutes to allow gas to dissipate and OFF wait 5 minutes to allow gas to repeat the lighting process Dissipate and repeat the lighting process 3 To light the other burners push and 3 Adjust the back burner control knob turn control knob one by one counter counter clockwise to desired cooking clockwise to HIGH position and adjust to temperature desired cooking temperature NOTE To light gas grill with a gas lighter make sure the grill has been leak tested and burners be properly located Remove the cooking grid and flame tamer from burner you wish to light Insert long necked gas lighter placing near to burner ports Press in the last right control knob Auto Ignition Knob and rotate left to HIGH setting to release gas Turn on the button on gas lighter burner should light immediately Place back the cooking grid and flame tamer Adjust burners to desired cooking temperature NOTE If for some reason igniters fail to light burners can be lit with a gas lighter Page 32 INSTALLNG COMPONENTS Rotisserie Installation A warnine Never stand with your head direc
58. not use water on grease fires Never pick up a flaming pan Turn the appliance off and smother the flaming pan with a tight fitting lid a cookie sheet or a flat tray For flaming grease outside of the pan smother it with baking soda or use a dry chemical or foam type fire extinguisher When your gas grill is not in use turn off the gas at the supply cylinder Storage of a grill indoors is permissible only if the supply cylinder is disconnected and removed We recommend commercial quality aluminum pans and utensils Never leave the grill and side burners unattended when in use When using pots and pans boil overs will cause smoking and greasy boil overs may ignite Spiders and other insects can nest in the burners of the grill and block the gas and airflow to the burner ports This creates a dangerous condition that can result in a fire behind the valve panel Inspect and clean the burners periodically and follow the guidelines in the Cleaning and Maintenance section of this manual Page 5 INSTALLATION AND ASSEMBLY Island Safety uos Improper installation adjustment alteration service or maintenance can cause injury or property damage Read the installation operating and maintenance instructions thoroughly before installing or servicing this equipment Placement and Location e Never locate this island in an enclosed room under any sealed overhead structure or any type of enclosed area such as a garage shed or breezeway and
59. nstitute illegal installations and cannot be serviced SEE FIG A Page 15 Do not use pipe thread sealant or Teflon tape on Brass flare ends You will not obtain a leak free seal Pipe Seal or Teflon tape is only used on Black Pipe Keep flare end of fitting and flare seats of connector nut free of grease oil pipe thread sealant and Teflon tape S Do not use a pipe wrench or channel lock pliers on the connector flare nut The nut can be damaged or you will not achieve sufficient tightening torque which will result in leaking gas Use open end or adjustable wrenches only Page 14 GAS INSTALLATION amp MAINTENANCE Configuring Adaptors Glossary Flare nut with V Hex Surface Flare Tapered beveled surface of connector nut or Flare Seat fitting where the seal occurs Pipe thread sealant or o alle p Teflon tape should never be applied to a flare surface Internal Male Pipe Threads the external pipe thread that protrudes from the fitting and fits into a female pipe thread Also referred to as MIP Male Iron Pipe Flare end insert into the connector flare nut do not apply pipe thread sealant or Male Pipe threads apply pipe thread R Teflon tape to this end vo f sealant or Teflon tape ED here Hex surface FIG A Sunstone Grill db CURODD T Flex Line 1 2 Flare Male Adapters Safety Shut Off Valves T Adapter to 2nd Appliance LP Regulator pe LL ED
60. nstructed and marked in accordance with the specifications for L P gas cylinders of the U S Department of Transportation DOT or the National Standard of Canada CAN CSA B339 Cylinders Spheres and Tubes for Transportation of Dangerous Goods and Commission as applicable and shall be provided with a listed overfilling prevention device 9 Read labels on the L P Gas Supply Cylinder e New cylinders are always shipped empty for safety e Allow only qualified L P gas dealers to fill or repair your L P gas supply cylinder e Inform the gas dealer if it is a new or used cylinder to be filled e After filling have the gas dealer check for leaks and to see that the relief valve remains free to function Propane vapors are heavier than air For this reason they may accumulate in low lying areas such as basements crawl spaces and ditches or along floors However air currents can sometimes carry propane vapors elsewhere within a building Page 17 GAS INSTALLATION amp MAINTENANCE Propane Tank Safety Hose and Regulator The Type 1 connection system has the following features e The system will not allow gas to flow until a positive connection has been made NOTE The cylinder control valve must be turned off before any connection is made or removed e The system has a thermal element that will shut off the flow of gas in the event of a fire e The system has a flow limiting device which when activated will limit the flow of gas to 10
61. orkmanship when subjected to normal domestic use and service for the lifetime of the original purchaser This warranty does not include discoloration surface corrosion and scratches which may occur during regular use LIMITED LIFETIME WARRANTY Sunstone Stainless Rod Cooking Grids and Stainless Steel Housings including liners frames ovens and barbecue faces are warranted for as long as you own you re Sun Barbecue Grill LIMITED THREE YEAR WARRANTY Sunstone Side burners and all other Sunstone Barbecue components including doors drawers Cocktail Station Ice Chest are warranted to be free from defects in material and workmanship for a period of three years from the original date of purchase LIMITED ONE YEAR WARRANTY All other grill components including igniters knobs valves tubing rotisserie motor light assembly and covers are warranted to be free from defects in material and workmanship for a period of one year from the original date of purchase LIMITATIONS amp EXCLUSIONS 1 SUNSTONE warranty applies only to the original purchaser and may not be transferred 2 SUNSTONE warranty is in lieu of all other warranties expressed or implied and all other obligations or liabilities related to the sale or use of its grill products 3 SUNSTONE warranty shall not apply and SUNSTONE is not responsible for damage resulting from misuse abuse alteration of or tampering with the appliance accident hostile environment flare up fires improp
62. orm with local codes or in the absence of local codes with either 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 1192M and CSA Z240 RV Series Recreational Vehicle Code as applicable LP Tank Removal Transport and Storage e Turn OFF all control knobs and LP tank valve Turn coupling nut counterclockwise by hand only do not use tools to disconnect Lift LP tank wire upward off of LP tank collar then lift LP tank up and off of support bracket Install safety cap onto LP tank valve Always use cap and strap supplied with valve Failure to use safety cap as directed may result in serious personal injury and or property damage 9 Adisconnected LP tank in storage or being transported must have a safety cap installed Do not store an LP tank in enclosed spaces such as a carport garage porch covered patio or other building Never leave a LP tank inside a vehicle which may become overheated by the sun The cylinder must be arranged for vapor withdrawal It must also include a collar to protect the cylinder valve A safety relief device having direct communication with the vapor space of cylinder must be provided This will expel high pressure gas if the cylinder is overfilled or overheated which could result in fire or explosion e All L P gas cylinders used with this appliance shall be co
63. osened DO NOT REMOVE SCREWS COMPLETLEY 3 Replace Knob back on Move Knob Ring Left Right Up and Down till it is Centered around Knob then remove knob while holding ring in place 4 Fasten all four screws tightly in place and replace knob back on valve stem Do this until knob turns freely and when pushed in releases properly Knob amp Valve Adjustment While turning any of the knobs and you notice any are loose and does not either turn gas on or turn off properly and or either one Auto lgnition Knob does not ignite burner follow these steps 1 Turn each knob for any issues 2 For knob that is loose remove knob and check to see if the inside black plastic guts are partially damaged IF DAMAGE TO KNOB IS NOTICED CONTACT SUNSTONE FOR KNOB REPLACEMENT BEFORE PROCEEDING 3 With Knob removed use Phillips Flat Head Screw Driver and very slightly push tip into valve slit at the head of Valve Stem to separate two sides and push them further apart DO NOT PUSH TOO HARD OR VAVLE STEM WILL SNAP ONLY 1 16 TO 1 8 IN IS USUALLY NEEDED 4 Replace Knob back on Valve Stem you should notice Knob is much tighter on Valve and turns gas flow on off properly Phillips Head i Screw Driver ala Page 73 APPENDIX Warranty SUNSTONE OUTDOOR GAS GRILL amp COMPONENT WARRANTY LIFETIME WARRANTY SUNSTONE Stainless steel burner and side burner Brass Burners to be from defects in material and w
64. pane The following illustrated conversion can be used for when converting either from LP to NG or NG to LP This example is shown with the Sunstone 4 Burner with Infra Red Burner Other Grills without a IR Burner can also follow this instructions the only difference is you are not required to change any Safety Valve or IR Orifice For converting gas types it is extremely important to follow these instructions step by step we always recommend a Licensed Plumber or Installer perform any maintenance or gas conversion on your grill Step by Step Instructions 1 Remove Drip Pan 2 Unscrew bolt connecting manifold pipe to grill body located at right back side of grill base 3 Unscrew the Left and Right small screws located below the control panel where drip pan was removed 4 Slide entire Control Panel and Valve assembly out from grill body 5 Disconnect all wires and flex lines from valves and igniter pay close attention to where they are all located 6 IRGRILLS ONLY Remove center knob unscrew Top and Bottom screws only 7 Flip control panel over on side so you have easy access to valves 8 IR GRILLS ONLY Unscrew base bracket hold center valve to gas manifold pipe and remove valve 9 IR GRILLS ONLY Install new Safety Valve in correct gas type follow the instructions in reverse 10 Locate the valve orifice at the ends of each valve it is either a small screw at the tip of valve or a long cylinder as shown in illustr
65. r local plumber to locate one that is made for commercial style grills For easier connections we recommend the Quick Connect Gas hose to make final connection THe Large Capacity Propane Tank is Required to be no oM UR 1 less than 10 Feet from any i appliance it is connected to do AN h EN 1 regulator is NOT provided the one provided with grill is for i Medium Propane Tank NOTE for Large Capacity Propane Tank hook up Individual LP Page 24 GAS INSTALLATION amp MAINTENANCE Natural Gas Tank Connection NG Gas Hook up This Natural Gas grill is designed to operate on Natural Gas ONLY at a pressure regulated at 7 water column W C when equipped with the correct natural gas orifices on the valves and a NG regulator on the supply line regulated at the residential meter ATTENTION Always turn grill knobs OFF before installing gas lines or making any connections and dis connections of supply hoses AX warnine Always take a leak test before lighting the grill to prevent a possible fire or explosion NG Quick Connect Hose Operation To connect push back sleeve of socket insert Plug release sleeve Push Plug until sleeve snaps forward locking Plug in Socket THIS TURNS GAS AUTOMATICALLY To disconnect Push sleeve back and pull out plug Uc aS ala A aci OFF GAS 7 NG Adapters Small Flexable Hose and Regulator are pre installed on grill Page 25
66. rce of such particles is from wirewool scouring pads but contamination may also occur from carbon steel utensils and old cast iron water supply pipes These brown marks are only superficial stains which will not harm the Grill they should be removable using a soft damp cloth and a multi purpose cream cleanser Occasionally it may be necessary to resort to a proprietary stainless steel cleanser to return the surface of the Grill to its original condition To avoid re occurrence of any rust staining it is essential that the source of the contamination be eliminated PITTING Another form of corrosion which occasionally occurs in stainless steel is pitting of the surface The reason for this corrosive attack can usually be attributed to certain household products Such as BLEACHES Most common domestic bleaches amp sterilizing solutions contain chlorine in the form of sodium hypochlorite If used in concentrated form bleaches can attack the stainless steel causing pitting of the surface They should always be used to the strengths prescribed by the manufacturer and should be thoroughly rinsed off with clean water immediately after use All cleaning agents containing hypochlorite are unsuitable for long term contact with stainless steel and even when used in the highly diluted form they can give pitting under certain conditions FOODSTUFFS In general stainless steel is fully resistant to all foodstuffs in common use Only in isolated case
67. rotisseries rod comes with a counter balance weight adjust it as needed Start the motor and make sure the meat is balanced on the spit so that it turns evenly You may need to adjust the grate and drip pan if your meat is large Make sure the meat can turn with no obstructions Close the lid while the rotisserie does its job The rotation evenly melts the fat in the meat and naturally bastes the meat but you may wish to baste with a mop sauce occasionally during grilling Check the meat with a meat thermometer for doneness before turning off the heat When done remove the spit using insulated oven mitts Place the meat on a clean platter and cover it with foil while it rests Page 58 USING YOUR GRILL Rotisserie Cooking Using Direct Heat Small or thin cuts of meat can be placed on the rotisserie directly over the heat source The meat cooks faster and is more like grilled meat The crisp cooked outside is then sliced off for serving and the remaining meat is returned to the grill Fig 1 With breasts down bring neck and skin up over cavity Fold under edges of skin skewer to keep in place Fig 1 Turn breast side up tie wings to body with twine Fig 2 Slide a meat fork on to spit rod and tighten Insert the spit rod in neck skin parallel to the backbone bring it out just above the tail Fig 3 Insert second meat fork on opposite side of spit rod and secure Make sure the bird is centered on the spit rod Tight
68. s such as when concentrated salt and vinegar mixtures are allowed to remain in contact with the steel for a long period can any surface marking result Page 65 APPENDIX Troubleshooting See page 27 28 QUESTION When I turn on my grill smell gas What should do Propane and Natural Gas have an additive scent known as mercaptan an acrid chemical to the gas so that you will recognize it immediately should there ever be a leak Mercaptan makes gas smell like sulphur or rotten eggs ANSWER Shut off the propane gas cylinder or natural gas service valve immediately Do not use the grill until the leak is fixed Any time you smell gas when operation grill you should immediately perform the Leak Test to identify the leak and fix it Please note that if you are using propane tank which includes a magnetic flow limiting device this safety mechanism may have been triggered The flow limiting device acts to limit the flow of gas if a leak is detected between the regulator and the burner valve s If the burner valve s is open prior to the LP gas cylinder service valve being opened the connection will interpret this free flow of gas to be a leak The connections safety feature will reduce gas flow from the regulator to the appliance to a minimal level Be sure that all burner valves are closed prior to opening the LP gas cylinder service valve to ensure that the connection flow limiting device is not triggered mistakenly If the conn
69. s injury BODILY INJURY Indicates a potentially hazardous situation which if not avoided may result in minor or moderate personal injury or property damage SURFACE Indicates an imminently hazardous hot surface which if not avoided will result in serious burn or injury Awe CIRCUIT Indicates a potentially hazard from Live electrical current that if extreme caution is not used may result in minor or moderate personal injury or property damage Aopen FLAME Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Page 3 INSTALLATION AND ASSEMBLY Grill Safety Sunstone safety instructions are located on the front control panel face panel Always read all instructions and warnings before proceeding or serious safety hazards can occur Read all instructions in this manual and front face of grill control panel before use We recommend that a licensed contractor install your Sunstone grill A caution 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 WARNING When Lighting the Grill Hold the Knob in until Burner Ignites DO NOT RELEASE KNOB GAS WILL CONTINUE TO FLOW When cooking Hood Closed Turn Burners to Low Heat A CAUTION Handle can become hot during u
70. s rated for up to 25 Pounds Rotisserie assembly can be purchased Name Qty Part No individually either by individual item or in a 3 Burner Rotisserie set 1 P RK 3B complete set for your size of grill The rotisserie A Burner Rotisserieset 1 P RKAB i assembly can also be used with or without an 5 Burner Rotisserie set 1 P RK 5B infra red back burner Electrical Grounding Instructions The rotisserie motor is equipped with a three prong grounding plug for your protection against electric shock This plug must be inserted directly into a properly grounded three prong receptacle Do not cut or remove the grounding prong from this plug The rotisserie motor must be electrically grounded in accordance with local codes or in the absence of local codes in accordance with the National Electrical Code ANSI NFPA 70 1990 or Canadian Electrical Code CSA C22 1 Do not use an extension cord to supply power to your grill Such use may result in fire electrical shock or other personal injury Do not install a fuse in the neutral or ground circuit A fuse in the neutral or ground circuit may result in an electrical shock hazard Do not ground this appliance to a gas supply pipe or hot water pipe Page 34 INSTALLNG COMPONENTS Side Burners Installation Side Burner Setup for Natural Gas For Natural Gas installation when installing an extra appliance like a side burner You will first need to
71. se NOTE TURN Turn In and turn OFF GAS SUPPLY when knob to Left to appliance is not in use allow gas to flow OFE First Postiion OFF When Lighting the Grill Second Position HIGH Hold the Knob in untill Burner Ignites DO NOT Third Position LOW RELEASE KNOB GAS WILL CONTINUE TO For Ignition Hold FLOW Knob in to hear clicking sound A warnine Failure to open the lid while igniting the barbecue s burners or not waiting 5 minutes to allow the gas to clear if the barbecue does not light may result in an explosive flame up which can cause serious bodily injury or death 1 2 3 Open Lid Before Lighting Burners Make sure all Control Knobs are in OFF position Push and Turn Last Right Knob next to the Black ignition cap to HIGH position 3 5 seconds to light burner If ignition does not occur in 5 seconds turn the last Right Knob to OFF wait 5 minutes to allow gas to dissipate and repeat the lighting process To light the other burners push and turn knob one by one counterclockwise to HIGH position to allow gas to flow To turn OFF turn each knob clockwise until it locks in OFF position Be sure to Push In to turn Knob Page 4 INSTALLATION AND ASSEMBLY Grill Safety ZA CAUTION Do Not close grill hood for more than 3 5 minutes with burners set to HIGH temperature or damage may occur to grill that is not covered under manufacture warranty A CAUTION When using your Sunstone Grill always
72. se bottles or metal cylinders contain propane a type of alkaline gas that has been compressed and transformed into liquid form Transporting storing and using propane safely can only be possible if it is held inside tanks or containers Since propane has various applications many types of tanks are being used as propane containers Below are some common examples Large Capacity Tanks Propane is delivered to your home as a very cold liquid and is pumped into a specially designed storage tank Fig A The liquid changes to gas before it leaves the tank Propane tanks are typically painted white or silver to reflect heat and prevent the pressure inside the tank from getting too high Fig A If you have an underground tank only the cover Fig B SE will be visible above ground gt e The cover on top of the tank protects several components from weather and physical damage including See Fig C Page 20 j e The tank shut off valve which you can close to a be stop the flow of propane to your home in case of a leak or other emergency e The regulator which controls the pressure of the propane gas coming out of the tank e The safety relief valve which will pop open automatically if the pressure inside the tank gets too high The valve will close again when the pressure returns to normal e The tank gauge which shows the percentage of MEET 7 AMAA Fig B propane in the tank Propane flows from your tank
73. surrounding objects Check to make sure that the burners and the drip tray are clean and free from obstructions Clean if necessary Page 66 APPENDIX Troubleshooting See page 29 32 QUESTION When I push in the knob my grill does not ignite ANSWER First determine if the spark igniters are functioning properly You should hear a rapid snapping sound when the igniter button is depressed If no sound is heard try replacing the igniter battery If the battery is good ensure that the proper gap exists between the burner and electrode wire If the spark igniters are working correctly next determine if gas is reaching the burners Check to see if any there are any signs of melted plastic around igniter box If you discover any bubbles or melted plastic you need to replace igniter box Ensure the gas supply is turned on and that there are no leaks Attempt to match light a burner If the burner will light with a match then the spark igniter may not be functioning correctly or may not be adjusted correctly If the burner will not match light and the gas supply has been confirmed then check the burner for blockages QUESTION See page 73 When I turn my grill burners on medium to low my grill blows out ANSWER First determine if the problem is being caused by location If location is subject to high winds reposition grill to provide some protection by placing the front of the grill toward the prevailing wind Check the gas supply an
74. t110 120 V AC Power Cord 6 cord with grounded plug Product Weight 138 LBS Cut out Size 21 3 4 10 7 8 PRODUCT SPECIFICATIONS E 1 AU 26 Height a A ad I t 34 Width 26 1 4 Height li 26 a Height 2 Depth i x 2 Lip 1 8 1 8 Hei ight t 23 1 2 Depth 25 1 4 Depth 27 Depth INSTALLATION SPECIFICATIONS Non Combustible Enclosure 21 3 4 Depth ER d Openning Width For Sunstone Accessorry Doors and Drawers Page 47 GRILL INSPECFICATION AND PARTS LIST SUN 4 Burner 34 Page 48 GRILL INSPECFICATION AND PARTS LIST SUN 4 Burner 34 SUN4B LP SUNAB NG Parts List NOTES No Description np Upper Hood 16 Control Panel Frame 17 I Burner 22 Smoker Box 23 Light Transformer 25 Hood Rubber Stopper m Bip eir N Part No Hood 4B Hood 4B H P TMeter P WR P GUBB P Lcover P GSet4B P GMP P Alvalve P Rsvalve P IIB P Knob L RB P Knob L P CP P Dtray P CPF P GBurner P FL 4B P FDivder P GBSF P LSB P SMBox P LT P HAB P HRS Page 49 GRILL INSPECFICATION AND PARTS LIST SUN Infrared 4 Burner 34 PRODUCT SPECIFICATIONS Model Options r NATURAL GAS SUN4B IR NG LIQUID PROPA
75. tHoles Clear any clogged port holes the holes where gas flame 1 exits the burner with a stiff Use TOOTH PICK wire or tooth pick rsen qe nos STAINLESS STEEL WIPE IN THIS DIRECTION OR WITH THE GRAIN After initial usage areas of the grill may discolor from the 4 amp gt A intense heat given off by the burners This is normal use a mild stainless steel cleaner and rub in the direction of the grain of the metal Specks of grease can gather on the m surface of the stainless steel and bake on to the surface and T give a worn appearance For removal use a nonabrasive p oven cleaner in conjunction with a stainless cleaner NOTE Always scrub in the direction of the grain lt G N Oe Page 64 APPENDIX Care and Maintenance ANNUAL CLEANING OF GRILL HOUSING Burn off the grill after use will keep it ready for instant use however once a year you should give the entire grill a thorough cleaning to keep it in top operating condition 1 Shut off gas supply at source and disconnects fuel line Protect fuel line fitting 2 Remove and clean the cooking grids flavorizors and burners 3 Remove warming rack and wash with mild detergent and warm water 4 Cover the gas valve orifices with a piece of aluminum foil 5 Brush the inside and bottom of the grill with a stiff wire brush and wash down with a mild soap and warm water solution Wash thoroughly and let it dry 6 Remo
76. tallation before completing connector installation Plug j 5 0 Quick Connect Sleeve To Grill gt la gt eTo Gas Source 1 2 Female Adapter 1 2 Female Adapter 12 Gas Hose To connect push back sleeve of socket insert To disconnect Push sleeve back and pull out Plug release sleeve Push Plug until sleeve snaps plug THIS AUTOMATICALLY SHUTS OFF GAS forward locking Plug in Socket THIS TURNS GAS AUTOMATICALLY Female Pipe Threads the internal pipe thread that receives a male pipe thread Also referred to as FIP Female Iron Pipe Female Pipe threads a insert male pipe not flared threads into this receptacle NOTES Page 16 GAS INSTALLATION amp MAINTENANCE Propane Tank Safety A warnine Never attach an unregulated gas line to the appliance Connection to an unregulated gas line can cause excessive heat or fire When the unit is not in use be sure to turn off the gas at the LP tank IMPORTANT Before connecting grill to gas source make sure BBQ Grill control knobs are in OFF position Verify the type of gas supply to be used either natural or LP and make sure the marking on the appliance rating label agrees with that of the supply All pipe sealants must be an approved type and resistant to the actions of LP gas Never use pipe sealant on flare fittings The installation of this appliance must conf
77. the prevailing wind blows toward the front of grill See fig A page 9 Windy Conditions Your Sunstone grill is specially designed to draw fresh air in through the front and in direct to the bottom burners When grilling the hot gases are then released through the back of grill through a venting system Using your grill in windy conditions may disrupt the front to back air flow If while the hood is closed and you fail to see the hood temperature gauge rise use extreme caution turn gas flow to OFF position if knobs are very hot turn gas off at source 9 For breezy days be careful not to leave the front hood down for more than 15 minutes when the burners are on Never leave grill unattended when in operation e If you suspect the grill is overheating using an oven mitt open the front hood Then adjust the burner control knob to off position e Orient the grill so the Prevailing winds are not blowing into the rear or side of grill See figure A Correct Way and figure B Wrong Way Page 9 CAUTION Any damage resulting from windy conditions causing overheating including melted knobs or igniter wires and impulse igniter box Also any discoloration from heat buildup is excluded from warranty coverage A NOTICE Ensure grill is installed with proper air flow for correct combustion air and cooling airflow Airflow MUST be maintained for the grill to perform as it was designed If airflow is blocked overheating will occur and
78. tly over the Grill when preparing to light the Rotisserie burner to prevent possible bodily injury Never operate Rotisserie Burner with main other burner s ON Warming Rack must be removed when Rotisserie Burner is ON Rotisserie is mostly used to cook large pieces of meat and poultry to assure slow even cooking The constant turning provides a self basting action making food cooked on a rotisserie exceptionally moist and juicy Rotisserie cooking generally requires 1 to 4 hrs to cook depending on the size and type of meat being cooked You can have rotisserie cooking with indirect heat with infrared rotisserie burner Preferred by professional chefs over other methods the intense heat is ideal for searing in the natural juices and nutrients found in quality meats For successful rotisserie the meat should be centered and balanced as evenly as possible on the spit rod to avoid overworking the rotisserie motor Refer to the illustrations on page 34 box 1 6 1 Attach Motor Bracket Assembly to the side of the barbecue frame can be mounted on either left or the right side of the frame using two screws and two nuts 2 Insert Rotisserie Motor onto Motor Bracket Assembly 3 Slide Prong Forks with the prongs facing away from the handle onto the Spit Rod So that any food item will be in the center between the two four prong forks 4 Assemble Key Washer Counter balance and handle to Spit Rod Slide Shaft Collar with long end towards han
79. ue am D 5202 8 3 m Connect mw Flow of Gas Gas Line NG Shut off the gas with the shut off valve near the appliance on the gas supply line If a shut off valve is not present on the gas line it is recommended that you consult a licensed plumber for proper installation before completing connector installation Turning Gas Flow OFF Female Pipe threads um ga insert male pipe not 8 Turn Handle Full 90 gt flared threads into this Degrees until it is tightly B receptacle A closed Natural Gas Regulator normalizes the gas pressure by sensing the gas pressure downstream of the regulator and adjusting its spring valve accordingly to deliver a constant flow of gas It is recommended to use a regulator for each appliance since natural gas is often delivered at a higher pressure than needed the pressure may also fluctuate Be sure to install Regulator f with the correct gas flow Gas Flows Gas Flows in direction Not installing the out to Grill Bud C S from Source Regulator correctly will cause Ve seriouse overheating issues Direction of Gas Flow Female Pipe threads insert male pipe Page 15 GAS INSTALLATION amp MAINTENANCE Configuring Adaptors Quick Connect 12 Hose with the shut off valve near the appliance on the gas supply line If a shut off valve is not present on the gas line it is recommended that you consult a licensed plumber for proper ins
80. ups NOTES Page 68 APPENDIX Gas Conversions Understanding Gas Appliance Conversions Making changes to an appliance so that it can utilize a different fuel is known as appliance conversion and involves the replacement of gas orifices valves and or regulators These internal connections and gas utilization fittings are designed to work with a particular gas that has a specific pressure Natural gas is a much lower pressure gas than propane and converting the appliance to one or the other gases requires that the differing pressure is compensated for In other words connecting a natural gas appliance to a propane piping system will result in appliance malfunction and possibly danger The reason for this is because natural gas orifices are larger than propane orifices strictly because of gas service pressure In this case the higher pressure gas flowing through a larger orifice will result in more gas through the burner and likely more flame an unnecessarily large flame Conversely trying to use a propane appliance with natural gas will likely result in a very small flame or no burner flame at all because of the lower pressure gas and the smaller orifice This is the underlying purpose of an appliance conversion from propane to natural gas or from natural gas to propane Additionally appliances cannot be converted from electricity to propane or vice versa Conversions between Natural Gas and Pro
81. ve aluminum foil from orifices and check orifices for obstruction 7 Check electrode 8 Reinstall flavorizors cooking grids and warming rack 9 Reconnect to gas source and observe burner flame for correct operation IMPORTANT You should NOT line the bottom of the grill housing with aluminum foil sand or any other grease absorbent substance Grease will not be able to drip into the drip tray and a grease fire may occur MAINTENANCE GUIDELINES 1 Keep outdoor cooking gas appliance area clear and free from combustible materials gasoline and other flammable vapors and liquids 2 Do not obstruct the flow of combustion and ventilation air 3 Keep the ventilation opening s of the cylinder enclosure free and clear from debris 4 Visually check burner flames Burner flames should be blue and stable with no yellow tips excessive noise or lifting 5 Clean outdoor cooking gas appliance including special surfaces with recommended cleaning agents if necessary 6 Checkand clean burner for insects and insect nests A clogged tube can lead to a fire beneath the grill RUST BROWN MARKS When this type of staining occurs it is unlikely that rusting of the stainless steel itself causes the marks Similar marks can be found with both porcelain and plastic sinks The rust marks are the result of small particles of ordinary steel which have become attached to the surface these have subsequently rusted in the damp environment The most common sou
82. w Intended for cooking fish and other lean foods and for all smoke cooking SEAR COOKING TIPS Even for the most experienced chef sear grilling can at first present a bit of a challenge By following these simple tips you will soon be producing juicer more flavorful foods than you have ever experienced before As a general rule foods will cook in less time than they would take on an ordinary grill By turning food frequently approximately every 2 minutes excessive charring is simply avoided SEARING IS KEY Sunstone grill allow you to sear in any burner location so long it s on HIGH HEAT setting and it will produce intense heat which will quickly sear all your meats Searing locks in flavor and juices while allowing the outer surface to absorb smoke and food aroma that is produced as grease and drippings are vaporized by the burner The result is a crisp flavorful outside with a tender juicy inside Just the result you want with most grilled foods 1 If you pre cook meat or poultry do so immediately before grilling 2 Never defrost meat at room temperature or on a countertop 3 Refrigerate leftovers within 2 hours of taking food off the grill 4 Never let the tray boil dry That could be hazardous as grease from fatty foods that have collected in the tray could ignite and possibly cause bodily injury or property damage 5 Use a meat thermometer to be sure food has reached a safe internal temperature 6 Always trim excess f
83. y opposite of the heaviest part of the poultry meat The counterbalance will be facing straight up at this point Tighten the counterbalance in position by turning the axle Fine adjustments can be made by sliding the weight up and down the axel and securing it with the thumb screw Fig B page 59 Note Position the counterbalance so it does not interfere with the side bucket 1 Insert the pointed end of the spit rod into the motor 2 Attach spit collar to the other end of the spit rod and position into the groove on side of the casting or universal rotisserie bracket A warnine Do Not close grill hood for more than 3 5 minutes with Burners set to HIGH Temperature or Damage may occur to grill that is not covered under manufacture warranty Using the Rotisserie Preheat the grill by setting all the burners on high once hot turn off all but the rear burner The spit hangs over the front or center burner so that the meat is not directly over the heat If your grill has burners on each side preheat the grill then turn the burners to low Place a drip pan on the grill below the meat Add about 1 2 inch of water to the drip pan Place the first pair of prongs onto the spit then push the meat onto the spit and into the prongs Add the other set of prongs and push them into the meat securely anchoring it onto the spit Tighten the wing nut that holds the prongs in place and attach the spit to the brackets on either side of the rotisserie The

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