SUMMITTM 475 & 675. Natural Gas Barbecues. Step-By-Step Guide THIS GAS APPLIANCE IS DESIGNED FOR OUTDOOR USE ONLY.

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1 SUMMITTM 475 & 675 Natural Gas Barbecues Step-By-Step Guide Summit 475 NG THIS GAS APPLIANCE IS DESIGNED FOR OUTDOOR USE ONLY. Summit 675 NG THIS GAS APPLIANCE IS DESIGNED FOR OUTDOOR USE ONLY. CANADIAN GAS ASSOCIATION R A P P R O V E D DANGER If you smell gas: 1. Shut off gas to the appliance. 2. Extinguish any open flame. 3. Open lid. 4. If odor continues, Keep away from the appliance and immediately call your gas supplier or your fire department. Leaking gas may cause a fire or explosion which can cause serious bodily injury or death or damage to property. WARNING 1. Do not store spare LP Cylinder within 10 feet (3m) of this appliance. 2. Do not store or use gasoline or other flammable liquids or vapors within 25 feet (8m) of this appliance. WARNING: Follow all leak check procedures carefully in this manual prior to barbecue operation. Do this even if barbecue was dealer assembled. NOTICE TO INSTALLER: These instructions must be left with the owner and the owner should keep them for future use. THIS GAS APPLIANCE IS DESIGNED FOR OUTDOOR USE ONLY. WARNING: Do not try to light this appliance without reading "Lighting" instructions section of this manual /98

2 READ CAREFULLY BEFORE INSTALLATION INSTALL GAS SUPPLY WE RECOMMEND THAT THIS INSTALLATION BE DONE BY A LICENSED PROFESSIONAL. General Specifications for Piping Note - Contact your local municipality for building codes regulating outdoor gas barbecue installations. In absence of Local Codes, you must conform to the latest edition of ANSI Z This barbecue is designed to operate at 4.5 inches of water column pressure (.1625 psi). Use only the regulator supplied with the cooking module. A manual shut-off valve must be installed outdoors, and be accessible, not in the built-in structure. An additional manual shut-off valve indoors should be installed in the branch fuel line in an accessible location near the supply line. Pipe compound should be used which is resistant to the action of natural gas when gas connections are made. The gas connections must be firmly attached to rigid, permanent construction. The information provided in this manual is general for typical installations. We cannot cover all possible installation ideas. We recommend prior to installation that you contact your municipality for local building codes and your local fire department for installation verification. You can also call Weber-Stephen Products Co. at SUMMIT ( ) and we will try and answer any questions you may have. Gas line piping If the length of line required does not exceed 50 feet, use a 5/8" O.D. tube. One size larger should be used for lengths greater than 50 feet. Gas piping may be copper tubing, type K or L; polyethylene plastic tube, with a minimum wall thickness of.062 inch; or standard weight (schedule 40) steel or wrought iron pipe. Copper tubing must be tin-lined if the gas contains more than 0.3 grams of hydrogen sulfide per 100 cubic feet of gas. Plastic tubing is suitable only for outdoor, underground use. Gas piping in contact with earth, or any other material which may corrode the piping, must be protected against corrosion in an approved manner. Underground piping must have a minimum of 18" cover. Test connections All connections and joints must be thoroughly tested for leaks in accordance with local codes and all listed procedures in the latest edition of ANSI Z DANGER Do not use an open flame to check for gas leaks. Be sure there are no sparks or open flames in the area while you check for gas leaks. This will result in a fire or explosion which can cause serious bodily injury or death, and damage to property. If you have any questions, contact the Weber-Stephen Customer Service Center at SUMMIT ( ). 2

3 BUILT-IN CONSTRUCTION GENERAL INFORMATION WARNING A Weber-Stephen Products Co. insulated sleeve must be used for any built-in installation. LOCATING YOUR BARBECUE When determining a suitable location for your barbecue installation, give attention to concerns such as exposure to wind, proximity to traffic paths, and keeping any gas supply lines as short as possible. Never locate the Weber Gas Barbecue in a garage, breezeway, shed, under an unprotected overhang, or other enclosed area. Locate the barbecue and structure so there is enough room to safely evacuate the area in case of a fire. CLEARANCE FROM NON-COMBUSTIBLE SURFACES OR STRUCTURES WARNING: Clearance from the outside walls of the sides and back of the insulated sleeve must be a minimum of 6 inches from a non-combustible surface. Measure from the outside wall of the insulated surface to the non-combustible surface. Figure 1. Refer to Install Gas Supply on page 2 before starting installation. NON- COMBUSTIBLE SURFACE CLEARANCE FROM COMBUSTIBLE SURFACES OR STRUCTURES WARNING: Clearance from the outside walls of the sides and back of the insulated sleeve must be a minimum of 24 inches from a combustible surface. Measure from the outside wall of the insulated surface to the combustible surface. Figure 2. Refer to Install Gas Supply on page 2 before starting installation. 24 inches COMBUSTIBLE SURFACE 24 inches Insulated sleeve Figure 2 24 inches Countertop WARNING: All countertop finished surfaces must be constructed of a noncombustible material. 6 inches 6 inches 6 inches Insulated sleeve Countertop Figure 1 WARNING: All countertop finished surfaces must be constructed of a noncombustible material. 3

4 BUILT-IN STRUCTURE CUTOUT DIMENSIONS All dimensions are to finished surfaces. BUILT-IN STRUCTURE SLEEVE DIMENSIONS A WIDTH C DEPTH B HEIGHT DIMENSIONS Figure 3 BUILT-IN CUTOUT DIMENSIONS Side Burner Tolerances A B C WT Weight (expressed in pounds) represents the total weight of the insulated sleeve and the cooking unit and does not include the permanent structure housing the sleeve. The sleeve must be supported from the bottom. Recommended cutout dimensions A through C include a nominal clearance dimension to facilitate installation. Any additional clearance must be within tolerances shown or fit-up of sleeve and built-in structure may be adversely affected. Countertop DIMENSIONS.625 TYP. TRIM OVERHANG Figure 5 BUILT-IN INSULATED SLEEVE DIMENSIONS Tolerances A B C WT Weight (expressed in pounds) represents the total weight of the insulated sleeve and the cooking unit and does not include the permanent structure housing the sleeve. Specified insulated sleeve dimensions A through C reflect the dimension to the mounting surface of the trim excluding the.625 trim overhang. If the supporting structure is going to have an electrical outlet for a rotisserie, it should be on the left side of the structure. Silicon sealant Figure 4 Before installing the sleeve, lay a bead of silicon sealant around the top perimeter and front sides of the structure in the areas that the flanges of the sleeve will rest. This will prevent moisture seepage. The sealant you use must have a temperature rating above 120 F. If necessary, caulk between the flange of the sleeve and finished countertop surface. WARNING: All countertop finished surfaces must be constructed of a noncombustible material. 4

5 BUILT-IN SLEEVE GAS LINE LOCATIONS VENTILATION Note: These drawings are only a reference. Front of sleeve Support tubes Support tubes A B Plan view View of left side Figure 7 View of right side Front of sleeve C Right side view Figure 6 DIMENSIONS BUILT-IN SLEEVE GAS LINE LOCATIONS Tolerances A B C The dimensions shown indicate the location of the gas line inlet flange in the insulated sleeve. The support members of the built-in structure must not impede passage of the gas lines. Area should be kept clear of sharp, jagged, or extremely abrasive surfaces to avoid possible damage to gas supply lines. Exercise caution when pulling gas lines through built-in structure. Note: Leave an access in the structure for gas supply and regulator service. View of front side Figure 8 View of back side Cross ventilation must be incorporated in the supporting structure. We recommend a minimum of 100 square inches of venting per side. Vents should be on two sides of the structure. Figures 5 and 6 are references only. Location of the vents should be from the center, outward. Locate the vents at both the bottom of the structure and at the top of the structure. The bottom vents should be as close to ground level as possible. Make sure the vent area is not blocked by interior supports of the structure. We recommend vents with screens. Access doors to the structure are not considered vents. Clean the vents periodically. DANGER: Failure to follow recommended minimum venting instructions can cause gas to collect in the structure in the event of a gas leak. This may result in a fire or an explosion which can cause serious bodily injury or death, and damage to property. 5

6 SUPPLIES NEEDED You will need a soap and water solution to check for gas leaks. (See Step "Check for gas leaks.") Note - The hardware size of nuts, bolts and screws is given. For example "1/4-20 x 2 inch bolt" means a bolt 1/4 inch in diameter with 20 threads to the inch, 2 inches long. On a small screw for example, "6-32 x 1/2 inch screw" means a number 6 screw, with 32 threads to the inch, 1/2 inch long. While we give much attention to our products, unfortunately an occasional error may occur. If a part is missing, do not go back to the store. Call the Weber Customer Service Center toll free SUMMIT ( ) to receive immediate assistance. Have your owner s manual and serial number of the barbecue available for reference. REMOVE PACKAGED CONTENTS Flavorizer bar (7) (Summit 475) (11) (Summit 675) Optional Steam-N-Chips smoker Cooking grate (2) (Summit 475) (3) (Summit 675) Warm-up basket Bottom tray Catch pan holder Catch pan Drip pan Tool holder (4) Regulator/Bracket Corrugated Hose 6

7 ADD COOKING MODULE CAUTION: Use two people to lift and install the cooking module. Lift the cooking module out of the packaging. The gas line will hang below the module. Lower the module on an angle into the sleeve so the control panel is under the front top rail. Figure 9. Guide the gas line through he access hole in the sleeve while lowering the module. MOUNT REGULATOR BRACKET We recommend that you install the regulator to a rigid structure. The regulator mounting bracket can be used to mount the regulator to the built-in structure. The gas line from the manifold is long enough to reach the mounted regulator. We have provided the means to make an SAE flare connection. Do not use pipe sealant on this connection. Front rail Flange View from right Figure 9 Lower the back of the cooking module down so it sets on the rear rail. Figure 10. Be careful not to scratch the paint of the cooking module when installing the module. The cooking module should be level, setting on the front and rear rails. Flange Front rail Rear rail View from right Figure 10 7

8 CONNECT GAS SUPPLY TO REGULATOR Hard pipe the gas supply to the inlet of the regulator. Refer to Install Gas Supply section on page 2. Connect the corrugated gas line to the regulator. Figure 11. Figure 12 shows the gas line and regulator assembled. Hard pipe the gas supply to the regulator. Figure 13. INSTALL FLAVORIZER BARS You will need: seven (Summit 475) or eleven (Summit 675) flavorizer bars Set the Flavorizer bars front to back over the burners in the slots of the Flavorizer Bar/cooking grill support. Figure 14 (a). Bracket Regulator Gas supply to manifold Summit 475 Figure 14 Flavorizer Bar/ cooking grill support Figure 11 Bracket Flavorizer Bar Regulator Gas supply to manifold Slot Figure 12 Bracket Summit 675 Figure 14 Gas supply to manifold Regulator Figure 13 Hard piped gas supply 8

9 INSTALL STEAM-N-CHIPS SMOKER You will need: Steam-N-Chips smoker. Remove the center Flavorizer bar (the one that is not over a burner). Set the handles of the Steam-N-Chips smoker on the Flavorizer bar holder. Figure 15 (a). Note: For directions on how to use the Steam-N-Chips smoker, see the Operating Guide. ADD COOKING GRATES You will need: two (Summit 475) or three (Summit 675) cooking grates. The cross-wire of the cooking grate goes down. Set the cooking grates in place next to each other. Figure 16. a) Figure 16 Summit 475 Figure 15 Summit 675 Figure 15 9

10 INSTALL WARM-UP RACK You will need: warm-up rack. Install one end of the warm-up rack into the hole on the right end of the lid and the other end into the slot in the left end of the lid. Figure 17 (a). a) INSTALL BURNER CONTROL KNOBS You will need: four (Summit 475) or six (Summit 675) burner control knobs. Push on the burner control knobs. Figure 18. Figure 18 Figure 17 10

11 INSTALL BOTTOM TRAY You will need: Bottom tray, catch pan holder, catch pan, and one drip pan. Slide the bottom tray into the mounting slots under the bottom of the cooking box with the finger grip of the catch pan toward you. Figure 21. CAUTION: Do not line the bottom tray with aluminum foil. It can cause grease fires by trapping the grease and not allowing grease to flow into the catch pan. Figure 19 Note: It may be easier to install the catch pan holder by removing the catch pan from the holder. Hook the ends of the catch pan holder into the hole in the bottom tray. Figure 20. Figure 21 Figure 20 View from front of the Cooking Box Mounting slots Tabs of bottom tray Figure 22 Put the foil drip pan into the catch pan. 11

12 CHECK FOR GAS LEAKS WARNING The gas connections of your Weber Gas Barbecue have been factory tested. We do however recommend that you leak check all gas connections before operating your Weber Gas Barbecue. Pull the front panel up and out of the cooking box assembly. Figure 25. Remove control panel burner control knobs, and front panel The control panel is separate from the front panel. The control panel needs to be removed before the front panel can be removed. Figure 23. Front panel Figure 25 Control panel Front panel Put your fingers under the front edge of the control panel, lift up, and pull evenly toward you. Figure 24 (a). Front edge of the control panel Figure 23 DANGER Do not use an open flame to check for gas leaks. Be sure there are no sparks or open flames in the area while you check for leaks. This will result in a fire or explosion which can cause serious bodily injury or death and damage to property. WARNING: You should check for gas leaks every time you disconnect and reconnect a gas fitting. You will need: a soap and water solution and a rag or brush to apply it. Note: Since some leak test solutions, including soap and water, may be slightly corrosive, all connections should be rinsed with water after checking for leaks. WARNING: Make sure all burner control knobs are in the OFF position, including the side burner, if the barbecue has a side burner. Turn on gas supply. (a) Front Panel Control Panel Figure 24 12

13 CHECK FOR GAS LEAKS b) Check for leaks by wetting the connections with the soap and water solution and watching for bubbles. If bubbles form or if a bubble grows there is a leak. Note - Since some leak test solutions, including soap and water, may be slightly corrosive, all connections should be rinsed with water after checking for leaks. WARNING: Do not ignite burners when leak checking. a) c) a) c) Manifold Manifold Summit 475 Figure 26 d) Manifold d) Summit 675 Figure 26 Manifold Check: a) Left valves to manifold connection. Figure 26 (a). b) Center valves to manifold connection. Figure 26 (b). (For Summit 675 only.) c) Right valves to manifold connection. Figure 26 (c). d) Gas line to manifold connection. Figure 26 (d) e) Leak check all gas supply connections. WARNING: If there is a leak at connection 26 (d), turn OFF the gas and retighten the fitting with a wrench and recheck for leaks with soap and water solution. If a leak persists after retightening the fitting, turn OFF the gas. DO NOT OPERATE THE BARBECUE. Contact your dealer. WARNING: If there is a leak at connections 26 (a), 26 (b), or 26 (c) turn OFF the gas. Do not operate the barbecue. Contact your dealer. When leak checks are complete, turn gas supply OFF at the source and rinse connections with water. 13

14 REINSTALL FRONT PANEL You will need: front panel. With the Weber logo to the left, slide front panel down into place. Figure 27. INSTALL TOOL HOLDERS You will need: four tool holders. Place the tool holder under the control panel and over the front panel on the right side. Figure 28 (a). Set the tool holder on top of the front panel and slide it to the left. Figure 27 Figure 28 a) 14

15 REINSTALL CONTROL PANEL You will need: control panel. Pull igniter buttons up until they stay in the up position. Place the control panel into the grooves on either side of the front of the cooking box. Push the control panel into place, using even pressure while pushing. Figure 29 (a). Use your fingers to lift the front edge of the control panel slightly and set it into the recess on both sides of the cooking box. Figure 29. REINSTALL BURNER CONTROL KNOBS You will need: four (Summit 475) or six (Summit 675) burner control knobs. Push on the burner control knobs. Figure 30. (a) Figure 30 Front Panel Control Panel Figure 29 REFER TO OPERATING GUIDE BEFORE LIGHTING BARBECUE 15

16 16 EXPLODED VIEWS FOR SUMMIT 475 NG

17 REPLACEMENT PARTS LIST FOR SUMMIT 475 NG 1 Left pivoting endcap 2 Shroud assembly 3 Stainless steel handle 4 Flavorizer bar / cooking grate holder (2) 5 Flavorizer bar (7) 6 Left fixed endcap 7 Crossover tube (2) 8 Left burner (2) 9 Right burner (2) 10 Burner control knob (4) 11 Igniter (2) 12 Igniter lock nut (2) 13 Igniter wire (black) (2) 14 Igniter wire (white) (2) 15 Gas catcher ignition chamber (2) 16 Manifold mounting clips (2) 17 Control panel 18 Igniter button (2) 19 Front panel 20 Match holder 21 Bottom tray 22 Catch pan holder 23 Catch pan kit 24 Left sleeve 25 Door stop bushing (2) 26 Plastic hinge bushing (2) 27 Bottom sleeve 28 Front door 29 Door knob 30 Thermometer mount assembly 31 Thermometer 32 Right pivoting endcap 33 Cooking grate (2) 34 Warm-up rack 35 Steam-N-Chips smoker 36 Hair pin cotter (2) 37 Clevis pin (2) 38 Rear shroud 39 Burner tube rest 40 Right fixed endcap 41 Cookbox assembly 42 Corrugated gas line (475/675) 43 Regulator mounting bracket 44 Regulator assembly 45 Manifold assembly 46 Tool holder (4) 47 Back sleeve 48 Rail (2) 49 Right sleeve 50 Plastic tube 51 Snap bushing (2) /8 screw (22) 53 Wire door hinge 54 Nylon washer (4) All items are single quantities unless otherwise specified. Parts can be ordered directly from Weber-Stephen Products Company by phone or mail. Note - Do not return parts to Weber-Stephen Products Co. without first contacting the Customer Service Center by phone or mail. Returning the part may not be necessary. While we give much attention to our products, unfortunately an occasional error may occur. If a part is missing, do not go back to the store. Call the Weber Customer Service Center toll free SUMMIT ( ) to receive immediate assistance. Have your owner s manual and serial number of the barbecue available for reference. Weber-Stephen Products Company Customer Service Center 250 South Hicks Road Palatine, IL (888) 33-SUMMIT ( ) WARNING: Use only Weber factory authorized parts. The use of any part that is not factory authorized can be dangerous. This will also void your warranty. 17

18 18 EXPLODED VIEWS FOR SUMMIT 675 NG

19 REPLACEMENT PARTS LIST FOR SUMMIT 675 NG 1 Left pivoting endcap 2 Shroud assembly 3 Stainless steel handle 4 Cooking grates (3) 5 Flavorizer bar / cooking grate holder (2) 6 Flavorizer bar (11) 7 Left fixed endcap 8 Crossover tube (3) 9 Left burner (3) 10 Right burner (3) 11 Burner control knob (6) 12 Igniter (3) 13 Igniter lock nut (3) 14 Igniter wire (black) (3) 15 Igniter wire (white) (3) 16 Gas catcher ignition chamber (3) 17 Manifold assembly 18 Manifold mounting clips (2) 19 Control panel 20 Igniter button (3) 21 Front panel 22 Match holder 23 Bottom tray 24 Catch pan holder 25 Catch pan kit 26 Left sleeve 27 Door stop bushing (2) 28 Plastic hinge bushing (2) 29 Bottom sleeve 30 Front door 31 Door knob 32 Thermometer mount assembly 33 Thermometer 34 Right pivoting endcap 35 Warm-up rack 36 Steam-N-Chips smoker 37 Rear shroud 38 Burner tube rest 39 Hair pin cotter (2) 40 Clevis pin (2) 41 Right fixed endcap 42 Cookbox assembly 43 Corrugated gas line (475/675) 44 Regulator mounting bracket 45 Regulator assembly 46 Tool holder (4) 47 Back sleeve 48 Rail (2) 49 Right sleeve 50 Plastic tube /8 screw (22) 52 Snap bushing (2) 53 Nylon washer (4) 54 Wire door hinge All items are single quantities unless otherwise specified. Parts can be ordered directly from Weber-Stephen Products Company by phone or mail. Note - Do not return parts to Weber-Stephen Products Co. without first contacting the Customer Service Center by phone or mail. Returning the part may not be necessary. While we give much attention to our products, unfortunately an occasional error may occur. If a part is missing, do not go back to the store. Call the Weber Customer Service Center toll free SUMMIT ( ) to receive immediate assistance. Have your owner s manual and serial number of the barbecue available for reference. Weber-Stephen Products Company Customer Service Center 250 South Hicks Road Palatine, IL (888) 33-SUMMIT ( ) WARNING: Use only Weber factory authorized parts. The use of any part that is not factory authorized can be dangerous. This will also void your warranty. 19

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