Charbroil Natural Gas Conversion Kit (2020 and Newer)

Introduction

This instruction manual provides detailed guidance for the safe and proper installation and use of your Charbroil Natural Gas Conversion Kit, Model 8216842R04A. This kit is designed to convert compatible Charbroil propane grills to operate on natural gas. It is essential to read and understand all instructions before beginning the conversion process.

Important Safety Information

WARNING: Failure to follow these safety instructions could result in fire, explosion, or carbon monoxide poisoning, which could cause property damage, personal injury, or death.

• Professional Installation Recommended: Gas appliance installation should be performed by a qualified installer, service agency, or gas supplier.
• Gas Supply: Ensure the natural gas supply line is properly installed and meets all local codes and regulations.
• Leak Testing: Always perform a leak test on all gas connections after installation or servicing. Never use an open flame to check for leaks. Use a soapy water solution.
• Ventilation: Use the grill only in well-ventilated areas. Do not use in garages, sheds, or any enclosed area.
• Modifications: Do not modify any components of this kit or your grill. Unauthorized modifications can be dangerous and will void the warranty.
• Before Servicing: Always turn off the gas supply at the source and disconnect the grill before performing any maintenance or servicing.
• Children and Pets: Keep children and pets away from the grill during operation and while it is cooling down.

Package Contents

Verify that all components listed below are present in your conversion kit:

• 10 FT Natural Gas Hose
• Orifice Removal Tool
• Quick Connect Fitting
• 6 Stop Pins

Image: Components of the Natural Gas Conversion Kit, including the 10 FT hose, quick connect, orifice removal tool, and stop pins.

Compatibility

This conversion kit is specifically designed for:

• Charbroil Dual Fuel grills (2020 model year or newer)
• Most Commercial Series™ and Signature Series™ grills (2020 or newer) with Dual Fuel capabilities
• Pro Series Grills (2020 or newer)

IMPORTANT: Do not use this kit for older grill models manufactured before 2020. Ensure your grill is compatible before attempting conversion.

Image: Visual representation of the natural gas conversion kit connecting a grill to a home's natural gas supply, highlighting its use for grills with up to 5 main burners and a side burner.

Setup and Installation

Follow these steps carefully to convert your propane grill to natural gas. It is recommended to have this procedure performed by a qualified professional.

Preparation

1. Ensure your grill is completely off and cool.
2. Disconnect the propane tank from the grill.
3. Turn off the natural gas supply at the main shut-off valve for your home.
4. Gather all tools required, including the orifice removal tool from the kit, wrenches, and a soapy water solution for leak testing.

Conversion Steps

5. Remove Propane Regulator: Locate and carefully disconnect the existing propane regulator and hose assembly from the grill's manifold inlet.
6. Install Natural Gas Quick Connect: Attach the quick connect fitting from the kit to the grill's manifold inlet. Ensure it is tightened securely to prevent leaks.
7. Replace Orifices: Access the burner valves. Using the provided orifice removal tool, carefully remove the propane orifices from each burner valve. Replace them with the natural gas orifices supplied in the kit. Ensure each orifice is seated correctly and tightened appropriately. This step is critical for proper gas flow and safety.
8. Install Stop Pins: For each control valve, locate the control knob stem. Install the stop pins onto the control valve stems. These pins limit the rotation of the control knobs, ensuring proper low flame settings for natural gas operation.
9. Connect Natural Gas Hose: Connect one end of the 10 FT natural gas hose to the quick connect fitting on the grill. Connect the other end of the hose to your home's natural gas supply line. Ensure all connections are tight.

Leak Testing

10. Slowly turn on the natural gas supply at the main shut-off valve.
11. Apply a soapy water solution (half liquid dish soap, half water) to all new gas connections.
12. Observe for bubbles. If bubbles appear, there is a leak. Immediately turn off the gas supply, tighten the connection, and re-test. Repeat until no bubbles are observed.
13. Wipe off any excess soapy solution.

Operating Your Converted Grill

After successful conversion and leak testing, your grill is ready for use with natural gas.

1. Ensure the natural gas supply is turned on.
2. Open the grill lid.
3. Turn one burner control knob to the HIGH position.
4. Press the igniter button (if applicable) or use a long-stemmed lighter to ignite the burner.
5. Once the first burner is lit, you can turn on and ignite additional burners as needed.
6. Adjust flame intensity using the control knobs. Natural gas flames should be blue with a slight yellow tip.
7. After cooking, turn all burner control knobs to the OFF position and close the natural gas supply valve.

Maintenance

Regular maintenance ensures the longevity and safe operation of your grill and conversion kit.

• Hose Inspection: Periodically inspect the natural gas hose for cuts, abrasions, or excessive wear. Replace immediately if any damage is found.
• Connection Checks: Annually, or if you suspect a leak, perform a leak test on all gas connections.
• Orifice Cleaning: If burners are not lighting properly or have weak flames, the orifices may be clogged. Consult your grill's manual for instructions on cleaning burner orifices.
• General Grill Cleaning: Keep your grill clean, especially the burner ports, to ensure efficient operation.

Troubleshooting

If you encounter issues after converting your grill, refer to the following common problems and solutions:

• No Gas Flow to Burners:
  • Ensure the natural gas supply valve is fully open.
  • Check for kinks or obstructions in the natural gas hose.
  • Verify all connections are secure and free of leaks.
• Low Flame or Uneven Heating:
  • Confirm that the correct natural gas orifices were installed. Propane orifices are smaller and will restrict natural gas flow.
  • Check for clogged burner ports or orifices. Clean as necessary.
  • Ensure the natural gas supply pressure is adequate. Consult your gas provider if unsure.
• Burners Not Igniting:
  • Verify gas flow as described above.
  • Check the igniter electrode for proper positioning and ensure it is clean.
  • If using a manual ignition, ensure the flame is applied directly to the burner ports.

If problems persist, contact Charbroil customer service or a qualified gas technician.

Specifications

Warranty and Support

For warranty information or to request manufacturer's warranty details, please contact Charbroil customer service.

• Manufacturer: Charbroil
• Customer Service Phone: 1-866-239-6777

Please have your model number (8216842R04A) and purchase information ready when contacting support.