CONVERSION INSTRUCTIONS Natural Gas to Propane Gas Conversion Kit For Thermador Professional Cooktops and Ranges Model STARLPKIT Part No. 35-00-682 Contains 7mm Hex Main Orifices This kit is used to convert only Professional Model PCS Professional Cooktops and Model PRDS Professional ranges from natural gas to propane gas operation. This kit cannot be used to convert older Thermador Professional cooktops or ranges, nor any other brand of appliance. PLEASE READ ENTIRE INSTRUCTIONS BEFORE PROCEEDING. IN CASE CONVERSION FROM PROPANE BACK TO NATURAL GAS IS DESIRED, ORDER PART NO. 35-00-679. COMPLETE THIS CONVERSION PRIOR TO INSTALLING APPLIANCE. IMPORTANT: INSTALLER: OWNER: Only a qualified service technician or installer should make this conversion. Please leave these Conversion Instructions with this unit for the owner. Please retain these instructions for future reference. WARNING: Disconnect gas and electric power before making conversion. Before turning power ON, be sure that all controls are in the OFF position.
! CAUTION: (1) When connecting the unit to propane gas, make certain the propane gas tank is equipped with its own high pressure regulator. The maximum gas pressure to this appliance is not to exceed 14.0 inches water column from the propane gas tank regulator. Tools/ Parts Required: Socket Driver - 1/4" Drive, 3"minimum extension 1/2" Open end Wrench Screwdriver 1/2" Deep Well Socket 1" Open end Wrench TABLE 1: Propane Conversion Kit Contents Description Part Number Ouantity Instructions, Propane Conversion 15-12-630 1 #112 Propane Orifice, Surface Burner 15-12-094 6 7mm Hex Socket 20-02-306 1 Foam Tape, 1" 20-02-059 1 Label, Propane Conversion 20-09-337 1 Plastic Bag 19-09-387 1 Carton 19-08-542 1 * The Propane Conversion Kit contains the indicated quantities of parts. However, some parts will not be used depending upon the model being converted. Refer to Table 2 for a listing of parts to be used and installation steps to follow for each particular model number. TABLE 2: Conversion Steps by Model Number Complete steps 1 and 2 for all cooktops and ranges, then follow additional steps as identified below for each particular model Replace Main Replace Wok Range Orifice for Main Burner Model Gas Surface Convert Convert Orifice & Pilot Number Burners Grill Griddle Burner Cap COOKTOPS PCS364GD Step 3 (4 each #112/1.12mm) -------- Step 5 -------- PCS364GL Step 3 (4 each #112/1.12mm) Step 4 -------- -------- PCS366 Step 3 (6 each #112/1.12mm) -------- -------- -------- PCS484GG Step 3 (4 each #112/1.12mm) Step 4 Step 5 -------- PCS484WK Step 3 (4 each #112/1.12mm) -------- -------- Step 8 PCS486GD Step 3 (6 each #112/1.12mm) -------- Step 5 -------- PCS486GL Step 3 (6 each #112/1.12mm) Step 4 -------- -------- RANGES PRDS304 Step 3 (4 each #112/1.12mm) -------- -------- -------- PRDS364GD Step 3 (4 each #112/1.12mm) -------- Step 5 -------- PRDS364GL Step 3 (4 each #112/1.12mm) Step 4 -------- -------- PRDS366 Step 3 (6 each #112/1.12mm) -------- -------- -------- PRDS484GG Step 3 (4 each #112/1.12mm) Step 4 Step 5 -------- PRDS486GD Step 3 (6 each #112/1.12mm) -------- Step 5 -------- PRDS486GL Step 3 (6 each #112/1.12mm) Step 4 -------- -------- PAGE 2
PROCEDURE TO CONVERT FROM NATURAL GAS TO PROPANE GAS FOLLOW STEPS 1 AND 2 FOR ALL COOKTOPS AND RANGES, THEN FOLLOW ADDITIONAL STEPS AS IDENTIFIED IN TABLE 2 FOR THE PARTICULAR MODEL BEING CONVERTED. STEP I: STEP 2: TURN OFF GAS AND ELECTRICITY If the appliance is installed: Shut off the gas valve to the appliance and remove appliance power cord from electrical outlet or turn breaker off at breaker box. CONVERT PRESSURE REGULATOR FROM 5" W.C. TO 10" W.C. The gas pressure regulator supplied with the unit is convertible from natural gas to propane gas. For cooktops, the regulator is mounted external to the appliance. For ranges, the regulator is mounted beneath the spill tray on the far left side. To access the range regulator, remove the aluminum Trim Strips from the spill tray sides (see Fig. 1A). Using the screwdriver, place it approximately 3" from either end of the trim, parallel to the spill tray surface so you can slide the screwdriver tip under the trim edges to lift up for removal. To remove spill tray, loosen and remove burner nut using 1" wrench as shown in Fig. 1B. Remove burner bases and disconnect wire to igniter. Remove spill tray and heat shield to access regulator. Reassemble in reverse order. Before you can reassemble spill tray trim, you must readjust all of the lancing on the trim. This will secure the trim (see Fig. lc). To operate correctly on propane gas, the pressure regulator must be converted as follows (see Fig. 1). a) REMOVE THE CAP from the top of the regulator. b) TURN THE CAP OVER, so that the letters LP can now be seen upright in the cap. c) REPLACE THE CAP into the top of the regulator, seating it firmly. Twist cap clockwise to lock in place. Make certain the spring located under cap remains in place. d) Finally, APPLY THE FOIL CONVERSION STICKER next to the rating plate, located on bottom corner of rough-in-box (cooktop) or behind the removable kick panel (ranges). FIGURE 1B PAGE 3
FIGURE 2 Burner Cap Flame Spreader 112 Star Grate (Top View) Burner Base STEP 3: CONVERT SURFACE BURNERS (ALL MODELS) A) REPLACE MAIN ORIFICES 1) REMOVE GRATES, BURNER CAPS and FLAME SPREADERS (see Fig. 2). 2) REMOVE MAIN SURFACE BURNER ORIFICES. ( 7mm Hex) This kit contains the orifices and the socket required to remove them. A method of retaining main orifices in the socket during extraction and insertion is to apply a piece of foam tape, supplied in the kit, to the socket, as shown in Fig. 3. Insert the socket driver with 3" minimum extension into the jet holders and remove existing orifices, as shown in Fig. 4. 3) INSTALL NEW MAIN SURFACE BURNER ORIFICES #112. Tighten propane orifices until snug. 4) REASSEMBLE. Install flame spreaders and burner caps (See Fig. 8). Replace grates. B) CONVERT VALVES FOR PROPANE GAS The bypass jet on each valve (see Fig. 5) must be adjusted as follows: 1) With all KNOBS IN OFF POSITION, REMOVE KNOBS. 2) LOCATE HOLE on control panel which is aligned to bypass screw. (see Fig. 5) 3) Insert screw driver in hole. TURN Bypass SCREW clockwise until bottomed out (approximately 1/2 to 3/4 turn), then back out (counter clockwise) 1/8 to 3/16 turn. See Fig 5A. 4) REPLACE KNOBS. FIGURE 6 Yellow Color is allowed ONLY at the tip of the Primary cone 5) CHECK FOR PROPER FLAME CHARACTERISTICS - Flame should be blue and stable with no yellow tips on the ends of the flame. Some yellow will appear in the flame of the tip of the primary cone (See Fig. 6). This is normal. No black carbon deposits should collect on the grates or any utensil. PAGE 4
STEP 4: STEP 5: CONVERT GRILL (MODEL NOS. PCS364GL, PCS484GG, PCS486GL, PRDS364GL, PRDS484GG, and PRDS486GL). a) REMOVE the grill grate, briquette pan, ceramic briquettes and the U-shaped burner. (Use extreme caution around the ceramic grill ignitor, it is very fragile). (See Fig. 7) Orifice is located on safety valve which is mounted to front chassis panel. b) USE A 1/2" DEEP WELL SOCKET to tighten down the grill burner orifice hood until it is tight against the pin. The orifice is located on the safety valve which is mounted on the front chassis panel. c) REASSEMBLE THE GRILL in reverse order. d) CHECK FOR PROPER FLAME CHARACTERISTICS Flame should be blue and stable with no yellow tips. (see Fig. 6). CONVERT GRIDDLE (MODEL NOS. PCS364GD, PCS484GG, PCS486GD, PRDS364GD, PRDS484GG, and PRDS486GD). a) COVER THE BULLNOSE AND SIDE TRIMS TO PREVENT DAMAGE. LIFT THE REAR OF THE GRIDDLE PLATE ASSEMBLY FIRST, then lift the front and slide the griddle plate carefully to the rear. (If the appliance is equipped with a backguard, cover the backguard to protect it during removal and reinstallation of griddle plate. Use extreme care around the ceramic griddle ignitor; it is very fragile.) b) REMOVE THE GRIDDLE THERMOSTAT BULB from beneath the griddle plate by sliding it out gently. c) REMOVE THE SCREW SECURING THE GRIDDLE BURNER, then remove the burner. d) USE A 1/2" DEEP WELL SOCKET to tighten down the griddle burner orifice hood until it is against the pin. DO NOT OVERTIGHTEN. The orifice is located on the safety valve which is mounted on the front chassis panel. e) REASSEMBLE THE GRIDDLE in reverse order. f) CHECK FOR PROPER FLAME CHARACTERISTICS - Flame should be blue and stable with no yellow tips. FIGURE 8 The burner flame should be blue in color and stable with no excessive noise or sputtering. It should burn completely around the burner cap. Slight yellow tipping in the primary cones of the flame kernel is normal with the Star Burner (See Fig. 6). Foreign particles in the gas line may cause an orange flame during initial use. This should disappear with use. If the flame does not burn evenly all the way around the burner cap, read What to do if you smell Gas, inside front cover of Installation Instructions. PAGE 5
FIGURE 9 STEP 8: CONVERT WOK (MODEL PCS484WK) a) REMOVE WOK MAIN BURNER. (See Fig. 9) b) TIGHTEN ORIFICE UNTIL SNUG. DO NOT OVER- TIGHTEN. c) OPEN FULLY THE AIR SHUTTER ON THE BURNER. d) REINSTALL WOK MAIN BURNER. e) TURN ON GAS SUPPLY, then check for gas leaks at the pilot body, 3/16" O.D. tubing and connections, main orifice location and manifold. f) CHECK FOR PROPER FLAME CHARACTERISTICS - Flame should be blue and stable with no yellow tips. g) CONVERT VALVES FOR PROPANE GAS The bypass jet on the valve (see Fig. 5) must be adjusted as follows: 1) With KNOB IN OFF POSITION, REMOVE KNOB. 2) LOCATE HOLE on control panel which is aligned to bypass screw. (see Fig. 5) 3) Insert screw driver in hole and TURN Bypass SCREW clockwise until bottomed-out (approximately 1/2 to 3/4 turn). (Fig 5A) 4) REPLACE KNOB. 5) CHECK FOR PROPER FLAME CHARACTERISTICS - Flame should be blue and stable with no yellow tips (see Fig. 6). PAGE 6
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Thermador is a leading manufacturer of Convection Micro Thermal Ovens, Convection Thermal Ovens, Thermal Electric Ovens, Warming Drawers, Free-Standing and Slide-In Ranges, Steel Gas ExtraLow Cooktops, Steel Gas Cooktops, Glass Gas ExtraLow Cooktops, Glass Gas Cooktops, Glass Ceramic Gas Cooktops, Glass Ceramic Dual-Fuel Cooktops, Glass Ceramic All-Radiant Cooktops, Glass Ceramic Halogen Cooktops, Electric Cooktops, Professional All-Gas Ranges and Cooktops, Professional Dual-Fuel Ranges, Cook n Vent Downdraft Ventilation System, Hoods, Ventilators, Housings, Dishwashers and Char-Glo Outdoor Barbecues. Specifications are for planning purposes only. Refer to installation instructions and consult your countertop supplier prior to making counter opening. Consult with a heating and ventilating engineer for your specific ventilation requirements. For the most detailed information, refer to installation instructions accompanying product or write Thermador indicating the model number. Thermador reserves the right to change specifications or design without notice. Some models are certified for use in Canada. Thermador is not responsible for products which are transported from the United States for use in Canada. Check with your local Canadian distributor or dealer. Thermador, 5551 McFadden Avenue, Huntington Beach, CA 92649. 5551 McFadden Avenue, Huntington Beach, CA 92649 800/735-4328 ECO15720 15-12-630C Thermador 1998 Litho U. S. A. 1/00