CONVERSION INSTRUCTIONS Propane Gas to Natural Gas Conversion Kit For Thermador Professional Cooktops and Ranges Model STARNGKIT Part No. 35-00-679 Contains 7mm Hex Main Orifices This kit is used to convert only Professional Model PCS Professional Cooktops and Model PRDS Professional ranges from propane gas to natural 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. MODEL GP24WK AND PCS484WK WOK COOKTOPS REQUIRE A SEPARATE KIT TO CONVERT THE WOK. ORDER WOKNGKIT, PART NUMBER 35-00-611. 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.
TABLE 1: Natural Gas Conversion Kit Contents Description Part Number Ouantity Instructions, Natural Gas Conversion 15-13-106 1 #168 Natural Gas Orifice, Surface Burner 15-12-591-01 6 7mm Hex Socket 20-02-306 1 Foam Tape, 1" 20-02-059 Plastic Bag 19-09-387 1 Carton 19-08-542 1 Gauge, Orifice Setting 15-12-209 1 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 * The 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 Range Orifice for Model Gas Surface Convert Convert Number Burners Grill Griddle COOKTOPS PCS364GD Step 3 (4 each #168/1.68mm) -------- Step 5 PCS364GL Step 3 (4 each #168/1.68mm) Step 4 -------- PCS366 Step 3 (6 each #168/1.68mm) -------- -------- PCS484GG Step 3 (4 each #168/1.68mm) Step 4 Step 5 PCS484WK Step 3 (4 each #168/1.68mm) -------- -------- PCS486GD Step 3 (6 each #168/1.68mm) -------- Step 5 PCS486GL Step 3 (6 each #168/1.68mm) Step 4 -------- RANGES PRDS304 Step 3 (4 each #168/1.68mm) -------- -------- PRDS364GD Step 3 (4 each #168/1.68mm) -------- Step 5 PRDS364GL Step 3 (4 each #168/1.68mm) Step 4 -------- PRDS366 Step 3 (6 each #168/1.68mm) -------- -------- PRDS484GG Step 3 (4 each #168/1.68mm) Step 4 Step 5 PRDS486GD Step 3 (6 each #168/1.68mm) -------- Step 5 PRDS486GL Step 3 (6 each #168/1.68mm) Step 4 -------- PAGE 2
FIGURE 1 Cap Position for Natural Gas NG PROCEDURE TO CONVERT FROM PROPANE GAS TO NATURAL 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 10" W.C. TO 10" W.C. The gas pressure regulator supplied with the unit is convertible from propane gas to natural 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 natural 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 NAT 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, REMOVE 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 168 Star Grate (Top View) Burner Base FIGURE 6 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 #168. Tighten orifices until snug. 4) REASSEMBLE. Install flame spreaders and burner caps (See Fig. 8). Replace grates. B) CONVERT VALVES FOR NATURAL 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 1/8 to3/16 turn), then back out (counter clockwise) 1/2 to 3/4 turn. See Fig 5A. 4) REPLACE KNOBS. 5) CHECK FOR PROPER FLAME CHARACTERISTICS - Flame should be blue and stable with no yellow tips on the ends of the flame. See Fig. 6. The burner flame should be blue in color and stable with no excessive noise or sputtering. It should burn completely around the burner cap. 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 Cooktop/Range Installation Instructions. PAGE 4
FIGURE 8 Safety Valve GUAGE Insert guage, gently screw orifice hood down against guage. GUAGE Unscrew orifice hood from LP Position STEP 4: 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) b) USE A 1/2" DEEP WELL SOCKET (with counter-clockwise rotation) to loosen the grill burner orifice hood. The orifice is located on the safety valve which is mounted on the front chassis panel. Set the spacing between the rear of the orifice hood and the safety valve body using the guage provided in the kit. See Fig. 8. c) REASSEMBLE THE GRILL in reverse order. d) Reset grill bypass jet for proper low rate operation. Verify that the jet is screwed into the valve body until bottomed out (This is normally done when converting to LP). Then unscrew the jet back out one (1) full turn. e) CHECK FOR PROPER FLAME CHARACTERISTICS Flame should be blue and stable with no yellow tips. Flame height should be approximately 1/4". STEP 5: 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 (with counter-clockwise rotation) to loosen the griddle burner orifice hood. The orifice is located on the safety valve which is mounted on the front chassis panel. Set the spacing between the rear of the orifice hood and the safety valve body using the guage provided in the kit. See Fig. 8. e) REASSEMBLE THE GRIDDLE in reverse order. f) CHECK FOR PROPER FLAME CHARACTERISTICS - Flame should be blue and stable with no yellow tips. Flame height should be approximately 3/4". PAGE 5
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 RO8585KIT 15-13-106A Thermador 1998 Litho U. S. A. 11/00