Weber SB38 S Built-In Gas Grill Installation Guide

This guide provides detailed instructions for the safe and proper installation of the Weber SB38 S Built-In Gas Grill.

Important Safety Information

Critical safety information is emphasized using DANGER, WARNING, and CAUTION statements.

DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING: Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

If you smell gas: Shut off gas to the grill, extinguish any open flame, open the lid. If the odor continues, keep away from the grill and immediately call your gas supplier or fire department.

WARNING: Do not store or use gasoline or other flammable liquids or vapors near this grill. An LP cylinder not connected for use shall not be stored near this grill or any other appliance.

USE OUTDOORS ONLY.

NOTICE TO INSTALLER: These instructions must be left with the consumer.

NOTICE TO CONSUMER: Retain these instructions for future reference.

Installation and Assembly Warnings

DANGER: This grill is not intended for installation in or on recreational vehicles or boats.
WARNING: Do not use this grill unless all parts are in place and properly assembled.
WARNING: Do not modify the appliance. Using natural gas in a propane unit or vice versa is unsafe and voids the warranty.
Professional installation of this natural gas grill is recommended.
Confirm the branch supply line to the grill is properly installed.
Installation must conform to local codes or national codes (e.g., National Fuel Gas Code, ANSI Z223.1/NFPA 54 in the US; CSA B149.1/B149.2 in Canada; Official Mexican Standard (NOM) in Mexico).
If an external electrical source is used, it must be electrically grounded according to local codes or ANSI/NFPA 70 / CSA C22.1.

Operation Safety

DANGER: Only use the grill outdoors in a well-ventilated area. Do not use in garages, buildings, breezeways, tents, enclosed areas, or beneath overhead combustible construction.
Outdoor installation is defined as having shelter with walls on no more than three sides, with no overhead cover, and all openings permanently open; or a partial enclosure with an overhead cover and no more than two sidewalls, all openings permanently open; or a partial enclosure with an overhead cover and three sidewalls, provided at least 30% of the horizontal periphery is permanently open.
If installed under overhead combustible construction, a UL 710- or ULC S646- approved heavy-duty vent hood must be used and in operation.
Minimum ambient operating temperature is 0°F (-17°C).
DANGER: Do not use the grill in any vehicle or storage/cargo area of any vehicle.
DANGER: Keep the grill at least 24 inches (61 cm) away from combustible materials (top, bottom, back, sides).
DANGER: Keep the cooking area clear of flammable vapors, liquids, and combustible materials.
DANGER: Do not place a grill cover or flammable items on or under the grill while it is operating or hot.
DANGER: In case of a grease fire, turn off all burners and leave the lid closed until the fire is out.
WARNING: Accessible parts may be very hot. Keep young children away.
WARNING: Alcohol or drug use may impair safe operation.
WARNING: Never leave the grill unattended during preheating or use.
WARNING: Do not move the grill during use.
WARNING: Keep electrical supply cords and fuel supply hoses away from heated surfaces.
CAUTION: This product is certified for use in a specific country.
Do not use charcoal or lava rock.
This natural gas grill is factory-built for natural gas only. Never operate on other gases.

Storage and Nonuse

WARNING: Turn off the gas at the natural gas supply valve when the grill is not in use.
After storage, check for gas leaks and burner obstructions before use.
Indoor storage is permissible only if the grill is disconnected from the gas supply.

California Proposition 65 Warnings

WARNING: Combustion byproducts contain chemicals known to cause cancer, birth defects, or other reproductive harm.
PROPOSITION 65 WARNING: Handling brass may expose you to lead, a chemical known to cause cancer, birth defects, or other reproductive harm. Wash hands after handling.

Electrical Supply

WARNING: Not for use by persons with reduced physical, sensory, or mental capabilities, or lack of experience, unless supervised.
WARNING: Children should be supervised to ensure they do not play with the appliance.
WARNING: Only use the provided power supply unit.
WARNING: Appliance has an earth connection for functional purposes only.
WARNING: Do not immerse cord or plugs in water or other liquid.
WARNING: Unplug when not in use and before cleaning. Allow to cool before handling parts.
WARNING: Do not operate with a damaged cord, plug, or after malfunction. Contact Customer Service via www.weber.com.
WARNING: Do not let the cord hang over edges or touch hot surfaces.
WARNING: Use only for intended purposes.
WARNING: Connect plug to appliance first, then plug appliance into outlet.
WARNING: Use only a Ground Fault Interrupter (GFI) protected circuit.
WARNING: Never remove the grounding plug or use with a 2-prong adapter.
WARNING: Use extension cords with a 3-prong grounding plug, rated for equipment power, and approved for outdoor use with a W-A marking. Do not connect multiple extension cords.

Planning Ahead: Configuration Options

Several configuration options exist for the grill and gas supply access within an island structure. The three common options (A, B, C) illustrate typical layouts.

Diagram Description (Page 2): Three diagrams (A, B, C) show different "Island" Structure Configuration Options for gas supply placement (1) relative to the built-in grill (2).

Local codes must be conformed to. Ventilation is required when using a gas supply system in an enclosure due to the explosive nature of gas vapor.

Planning Ahead: Recommended Construction Materials

Installation in a masonry structure by a professional is recommended. Preferred materials include stone, brick, marble, or granite countertops. Other noncombustible materials and metal studs may be used. Wood or other combustible materials are not acceptable.

Contact your local municipality for building codes regulating outdoor gas grill installations.

Planning Ahead: Ventilation

Cross-ventilation must be incorporated into the supporting structure. A minimum of 100 square inches (254 sq cm) of venting per side is recommended, with vents on two sides.

Diagram Description (Page 3): Illustrates the placement of ventilation holes at the bottom and top of the structure to provide cross-ventilation. Vents should be screened to prevent rodents and insects, and kept clear of debris. Bottom vents should be close to ground level and not blocked by interior supports.

DANGER: Failure to follow minimum ventilation instructions can cause gas to collect, leading to fire or explosion.
WARNING: Ventilation openings must be provided, with at least one high and one low, for cross-ventilation in case of a gas leak.
WARNING: Keep ventilation openings free of debris.

Planning Ahead: General Construction

The built-in unit should be on site before construction begins. The installation requires a level floor pad and countertop surface constructed from solid, level, and smooth materials. Proper subgrade materials are necessary to prevent settling.

If an electrical outlet for a rotisserie (sold separately) is planned, it should be on the right side of the structure.

Diagram Description (Page 4): Shows the overall grill dimensions and the required cutout dimensions for the built-in installation. Key dimensions include overall width, depth, height, and the specific width, height, and depth of the cutout opening, with tolerances.

Planning Ahead: Positioning Your Grill

Consider wind exposure, traffic paths, and keeping gas supply lines short when choosing a location. Never locate the grill in a garage, breezeway, shed, under an unprotected overhang, or any other enclosed area. The grill must not be installed under overhead combustible construction.

If installed under overhead combustible construction, a suitable UL 710- or ULC S646- approved heavy-duty vent hood must be used and in operation.

Ensure there is enough room to safely evacuate the area in case of a fire.

Planning Ahead: Clearance From Combustible Materials

Clearance dimensions indicate the minimum allowable distance from the edge of the grill to any combustible materials. The cut-out structure, countertops, and adjacent work areas must be constructed from noncombustible materials only.

Diagram Description (Page 5): Illustrates the minimum clearance requirements. It shows the barbecue must be 24 inches (610 mm) from any combustible surface or structure on the back and sides.

WARNING: The structure, countertops, and adjacent work areas must be constructed from noncombustible materials only.

Contact local building suppliers or fire departments for clarification on noncombustible materials.

Planning Ahead: Planning the Gas Supply Location

A 58-inch (147 cm) main corrugated gas line connects to the grill manifold. Build an opening for this line to pass through to the gas supply enclosure, where connections to the bulkhead, hose, and regulator are made.

Leave access in the "island" structure for gas supply and regulator service, located outside the grill cabinet and unobstructed after installation. A manual shutoff valve should also be installed in an easily accessible location.

The gas supply enclosure must house the included hose and regulator assembly and meet requirements for venting and separation from heat sources.

Diagram Description (Page 6): Shows the "Built-In Gas Line Location" with a plan view and side view. It indicates the gas inlet (b) and dimensions for the opening, emphasizing the need for an accessible enclosure (1) for the gas supply, bulkhead (2), and hose/regulator connections.

Diagram Description (Page 6, General Specifications): Lists key specifications including the grill's operating pressure (4.0" water column) and notes on quick-disconnect fitting installation (horizontal or downward), dust covers, and the requirement for an accessible outdoor manual shutoff valve and an indoor shutoff valve.

Diagram Description (Page 6, Gas Line Piping): Details piping requirements: 5/8" O.D. tube for lines up to 50 feet, larger size for longer runs. Acceptable piping materials include copper tubing (type K or L), polyethylene plastic tube (for underground use), or steel/wrought iron pipe. Corrosion protection and minimum 18" cover for underground piping are specified.

Diagram Description (Page 6, Hose Requirements): States that the model-specific hose attached during manufacturing must be used. Contact Customer Service if the hose is worn or damaged.

Diagram Description (Page 6, Pressure Testing): Instructions for pressure testing the gas supply: disconnect the grill for tests over 1/2 psig (3.5 kPa), or isolate with a shutoff valve for tests at or below 1/2 psig.

Diagram Description (Page 6, Connection Testing): All connections must be tested for leaks according to local codes and Owner's Manual procedures.

Diagram Description (Page 7): "Typical NG Grill Pipe Installation" shows the connection from inside the house (gas supply, shutoff) to outside the house (quick-disconnect, pipe nipple, locking shutoff). Local codes may require different installations; flare fittings should never be used.

Diagram Description (Page 7): "Mounting the Bulkhead" instructs to securely mount the bulkhead bracket to the side of the gas supply enclosure using non-corrosive hardware (not included).

DANGER: Use of any other hose and regulator assembly is dangerous and may result in fire or explosion.

DANGER: Do not use a flame to check for gas leaks; be aware of sparks or open flames.

DANGER: Leaking gas may cause fire or explosion. Do not operate if a leak is present.

CAUTION: Consider a locking valve if young children are present.

Construction Details: Built-In Cutout Detailed Dimensions

These diagrams provide specific measurements for locating the structure near combustible or non-combustible walls.

Diagram Description (Page 8): "BUILT-IN CUTOUT DETAILED DIMENSIONS - LOCATING THE STRUCTURE NEAR A COMBUSTIBLE WALL". This diagram shows clearances required when the grill is placed near combustible materials. Key dimensions include: 24" (610 mm) minimum clearance from cutout edge to combustible construction (1), 0" minimum to non-combustible surfaces (2), 12" (305 mm) for countertop overhang (3), 4" (102 mm) for gas inlet (4), 26 1/2" (673 mm) for the grill's side panel (5), 36" (914 mm) maximum width for the structure (6), 41 1/2" (1054 mm) for the grill's overall width (7), 24" (610 mm) minimum for an LP cylinder (8), and 3/4" (19 mm) minimum for countertop treatment (9). Gas inlet is labeled (b).

Diagram Description (Page 9): "BUILT-IN CUTOUT DETAILED DIMENSIONS - LOCATING THE STRUCTURE NEAR A NONCOMBUSTIBLE WALL". Similar to Page 8, but emphasizes 0" minimum clearance (2) to non-combustible surfaces. Key dimensions include: 24" (610 mm) minimum clearance from cutout edge to combustible construction (1), 0" minimum to non-combustible surfaces (2), 12" (305 mm) for countertop overhang (3), 4" (102 mm) for gas inlet (4), 26 1/2" (673 mm) for the grill's side panel (5), 36" (914 mm) maximum width for the structure (6), 41 1/2" (1054 mm) for the grill's overall width (7), 24" (610 mm) minimum for an LP cylinder (8), and 3/4" (19 mm) minimum for countertop treatment (9). Gas inlet is labeled (b).

General Clearance Note: Minimum 24" (610 mm) clearance from the back and sides of the barbecue to any combustible surface or structure applies.

Assembly

Assembly requires a flat, level, and soft surface. Remove protective film from stainless steel parts before installing. Do not use power tools. Three people are required for assembly. Keep the lid closed during assembly or moving.

Included Tools:

Allen Keys (various sizes)
7/16" Wrench

Required Tools:

7/16" Wrench

Parts List: (Illustrations show quantities of each part)

Main Body/Cookbox Components
Side Panels
Control Panel
Burners
Grates
Warming Rack
Ignition System Components
Doors/Panels
Casters/Legs

Hardware List:

Hardware Pack A: Screws, Bolts (e.g., -2 A, -1 A)
Hardware Pack B: Bolts, Washers (e.g., -1 B)
Hardware Pack C: Screws, Nuts (e.g., -4 C, -6 C, -2 C)
Hardware Pack D: Bolts, Brackets (e.g., -2 D)

Note: Specific part numbers and quantities are detailed in the original manual's illustrations.

Prepare Barbecue for Installation

Ensure all assembled parts are in place and fasteners are tightened. Place the barbecue directly in front of the built-in structure's cutout opening.

Diagram Description (Page 19): Shows the barbecue being pushed into the cutout opening and the front casters being locked by rotating them beneath the cabinet.

Connect Gas Supply

A 58-inch (147 cm) main corrugated gas line is connected to the grill manifold.

Diagram Description (Page 20): "CONNECTION CHART". This diagram illustrates the connection process. The corrugated gas line (7) is passed through the island structure cavity to the bulkhead (8) inside the gas supply enclosure (1). The gas line connects to the 1/2 inch flare fitting on the bulkhead. A 3/8 inch flared gasket is included but is NOT needed for this natural gas installation (indicated by 3/8" (9.5 mm) cap - DO NOT REMOVE). The diagram also shows the typical gas supply cabinet location (3) and side/top views of the enclosure.

Note: 3/8 inch (9.5 mm) flared gaskets are included for future 3/8 inch gas accessory connections but are not needed for this installation.

Diagram Description (Page 21): Shows the installation of filler strips to fill gaps at the countertop or front of the barbecue as needed.

Refer to Weber Crafted Outdoor Kitchen Collection accessory instructions and the Owner's Manual for features, usage, and rotisserie operation.

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