hestan KGC User & Installation Manual

INDOOR COOKING

Drop-in Gas Cooktop

KGC

Installation Manual

SAFETY DEFINITIONS

READ THESE INSTRUCTIONS CAREFULLY AND COMPLETELY BEFORE INSTALLING OR USING YOUR APPLIANCE TO REDUCE THE RISK OF FIRE, BURN HAZARD, OR OTHER INJURY. KEEP THIS MANUAL FOR FUTURE REFERENCE.

CAUTION

NOTICE

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS:

1) Do not try and light any appliance.

2) Do not touch any electrical switch.

3) Do not use any phone in your building.

4) Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

5) If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency, or the gas supplier.

IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED

EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING

PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

INSTALLER: LEAVE THIS MANUAL WITH THE OWNER OF THE APPLIANCE. HOMEOWNER: RETAIN THIS MANUAL FOR FUTURE REFERENCE.

THIS INDICATES THAT DEATH OR SERIOUS INJURY MAY OCCUR AS A RESULT OF NOT OBSERVING THIS WARNING.

THIS INDICATES THAT MINOR OR MODERATE INJURY MAY OCCUR AS A RESULT OF NOT OBSERVING THIS WARNING.

THIS INDICATES THAT DAMAGE TO THE APPLIANCE OR PROPERTY MAY OCCUR AS A RESULT OF NOT OBSERVING THIS WARNING.

When properly cared for, your Hestan appliance will provide safe, reliable service for many years. When using this appliance, basic safety practices must be followed as outlined below.

IMPORTANT: Save these instructions for the local Gas or Utility Inspector’s use.

INSTALLER: Please leave these Installation Instructions with the owner.

OWNER: Please retain these Installation Instructions for future reference.

This cooktop is designed for residential use only.

Do NOT install this cooktop outdoors.

SAFETY PRECAUTIONS - BEFORE YOU BEGIN

ELECTRICAL SHOCK HAZARD

Disconnect power before installing or servicing appliance. Before turning power ON, be sure all controls are in the OFF position. Failure to do so can result in death or electrical shock.

ELECTRICAL GROUNDING

This appliance must be grounded. Grounding reduces the risk of electric shock in the event of a short circuit. Read the ELECTRICAL CONNECTIONS section of this manual for complete instructions.

TABLE OF CONTENTS

1 SAFETY PRECAUTIONS - BEFORE YOU BEGIN 2 MODELS AND RATINGS 3 RATING LABEL 3 REGULATORY / CODE REQUIREMENTS 4 LOCATION AND INSTALLATION 12 GAS CONNECTION 16 ELECTRICAL CONNECTION 17 VENTILATION REQUIREMENTS 18 GAS CONVERSION 22 FINAL SETUP 25 PARTS LIST 25 SERVICE

MODELS AND RATINGS

COOKTOP MODELS

MODEL NO. DESCRIPTION

CIRCUIT BREAKER REQUIRED

KGC30 NG / -LP 30” DROP-IN GAS COOKTOP 15 Amp KGC36 NG / -LP 36” DROP-IN GAS COOKTOP 15 Amp

RATINGS

KGC 30

POWER Btu/h with NG

at 5inch W.C.

POWER Btu/h with LP

at 10inch W.C. Zones max flow rate min flow rate max flow rate min flow rate Front right 8000 1300 6000 1300 Front left 8000 1300 6000 1300 Rear left 10500 2200 10500 2200 Rear right 10500 2200 10500 2200 Center – simmer 850 850 Center – main flame 20000 20000

KGC36

POWER Btu/h with NG

at 5inch W.C.

POWER Btu/h with LP

at 10inch W.C. Zones max flow rate min flow rate max flow rate min flow rate Front right (Stacked B) 15000 1300 15000 1300 Front left (Stacked B) 15000 1300 15000 1300 Rear left (Stacked B) 15000 1300 15000 1300 Rear right (Stacked B) 15000 1300 15000 1300 Center – simmer 850 850 Center – main flame 20000 20000

REGULATORY / CODE REQUIREMENTS

Installation of this cooking appliance must be made in accordance with local codes. In the absence of local codes, this unit should be installed in accordance with the National Fuel Gas Code

ANSI Z223.1/NFPA 54

, Natural Gas and Propane Installation code

CSA B149.1

, or

Propane Storage and Handling Code

B149.2

All Electrical Components must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code

ANSI/NFPA 70

, or Canadian

Electrical code

CSA C22.1

STATE OF MASSACHUSETT S

Massachusetts requires all gas be installed using a plumber or gas fitter carrying the appropriate Massachusetts license. All permanently installed natural gas or propane installations require a T handle type manual gas valve be installed in the gas supply line to this appliance. Flexible gas connector must not be longer than 36” [91.4 cm].

CALIFORNIA PROPOSITION 65 - WARNING

WARNING This product can expose you to chemicals including carbon monoxide, which is known to the State of California to cause cancer.

For more information, go to www.P65Warnings.ca.gov.

RATING LABEL

There are two rating labels on the unit. The main label contains important information about your Hestan appliance such as the model and serial number, gas type and electrical rating.

Both rating labels are located in the bottom of the cooktop unit. Make sure you record your model number and serial number for future use. The second rating label contains information about the gas requirements and usage.

If service is necessary, contact Hestan Customer Care with the model and serial number.

Figure 1.

Rating Label Locations

KGCXX

HESTAN COMMERCIAL CORP.

ANAHEIM, CA - USA

XXX XXXXXX

xxxxxxxxx xxxxxxxxx xxxxxxxxx

Figure 2.

Sample Rating Label

LOCATION AND INSTALLATION

PLACEMENT

Check location where cooktop will be installed. The location should be away from strong drafty areas, such as windows, doors and strong heating vents or fans.

UNPACKING

Do not remove the plastic film covering the stainless-steel surfaces. This film protects the finish from scratches until the appliance is installed in its final position.

PR EPARATION

Electrical grounding is required. See “ELECTRICAL CONNECTION” on page 16 .

Assure that electrical installation is adequate and in conformance with National Electrical Code, ANSI/NFPA 70 - latest edition**, or Canadian Electrical Code, part 1 C22.1 (latest edition)*** and all local codes and ordinances.

Assure that the gas connection conforms with local codes and ordinances. In the absence of local codes, installations must conform with American National Standard, National Fuel Gas Code ANSI Z223/NFPA 54 - latest edition** Canadian CAN/CGA_B 149.1 or CAN/CGA-149.2 latest edition**

Copies of the standards listed may be obtained from: ** National Fire Protection Association

One Batterymarch Park

Quincy, Massachusetts 02169-7471

*** CSA International

8501 East Pleasant Valley Rd. Cleveland, OH 44131-5575

GAS AND ELECTRICAL SUPPLY CLEARANCES

If not already in place, install a gas shut-off valve in an easily accessible location for servicing of the cooktop. Make sure all users of the cooktop know where this shut-off is located, and how to shut off the gas. Any openings in the wall or floor behind the appliance must be sealed. See

Figure 8

and

Figure 9

on page6 for cutouts and clearances.

CABINETRY

To eliminate the risk of burns or fire by reaching over heated surface units, cabinet storage space located above the surface units should be avoided. If cabinet storage is to be provided, the risk can be reduced by installing the required vent hood that projects horizontally a minimum of 5” [12.7 cm] beyond the bottom of the cabinets.

INSTALLING COOKTOP OVER OVEN

Only certain specified cooktop and oven models are approved for cooktop over oven installations.

Cooktops approved for this type of installation will have an approval label located on the outside of the burner box. The label lists the cooktop and oven combinations that are approved for this type of installation.

If you do not find this label, contact your dealer to confirm that the cooktop is approved for installation over your model of oven.

GAS

SUPPLY

APPLIANCE

SHUTOFF VALVE

IN OPEN POSITION

Figure 3.

Gas Shut-Off Valve

LOCATION AND INSTALLATION

(continued)

COOKTOP DIMENSIONS

REGULATOR CLEARANCE

The regulator may mounted to the cooktop directly or via a flexible (semi–rigid) stainless steel gas hose with appropriate end fittings.

(See “GAS CONNECTION” on page 13 for more information)

30” [76 cm]

2-15/16” [7,4 cm]

20-1/16” [51 cm]

Figure 4.

30” Model

36” [91 cm]

2-15/16” [7,4 cm]

20-1/16” [51 cm]

Figure 5.

36” Model

6 1/4"

[159]

5 1/8"

[129]

Figure 6.

Regulator clearance

LOCATION AND INSTALLATION

(continued)

COUNTERTOP

1) Chamfer all exposed edges of decorative laminate to prevent damage from chipping.

2) Radius corners of cutout and file to ensure smooth edges and prevent corner cracking.

3) Recommend 1/4”or 3/8” diameter drill in each corner.

4) For solid surface countertops, refer to countertop material manufacturer instructions.

SOLID SURFACE COUNTERTOPS

Important: For solid surface material installations such as Surel™ and Corian®, consult with solid surface manufacturer. Apply heat reflective tape such as Scotch® Aluminum Foil Tape #425 or #427 around the cutout so that it folds over on the top and sides.

DO NOT WRAP THE TAPE UNDERNEATH THE COOKTOP.

Be sure the tape extends beyond the outermost flange of the cooktop. All corners should be covered with tape.

NEW INSTALLATIONS

For new installations, the minimum cut-out size is preferable.

Figure 7.

Solid Surface Protective Tape

Figure 8.

Cutout Requirements (1/2)

Cooktop

Size

A B C D

30” MIN.29” [73.7 cm]

MAX.29-1/2” [75.0 cm]

MIN 19-5/8” [49.9 cm] MAX 20” [50.8m cm]

MIN 2” [5.0 cm]

MIN 3 1/2” [9.0 cm]

36” MIN 35” [89.0 cm]

MAX 35-1/2” [90.2 cm]

MIN 19-5/8” [49.9 cm] MAX 20” [50.8m cm]

MIN 2” [5.0 cm]

MIN 3 1/2” [9.0 cm]

LOCATION AND INSTALLATION

(continued)

A 13” [33 cm) Depth of unprotected overhead

cabinets.

B 30” Model: 30” [76.2 cm] MIN.

36” Model: 36” [91.4 cm] MIN. C 18” [47.7 cm] MIN. Height from countertop to nearest cabinet on either side of unit. D 30” [76.2 cm ] MIN. (see Note*) Clearance from countertop to unprotected overhead surface. E 5” [12.7 cm] min Clearance from cut out to side wall on the left and right of the unit. F From the back corner of cut-out to hole center 2-9/32” [5.8 cm]. G From the right corner of cut-out to hole center 2-19/32” [6.6 cm]. H From the back corner of cut-out to hole center 1-1/4” [3.2 cm]. Opening with oven under

cooktop. I From the top of countertop to hole center 6” [15.2 cm]. Opening with oven under cooktop. L Electric outlet from bottom of counter top and adjacent to the cabinet side 12” [30.5 cm].

– Hole 1-1/5” [3 cm].

* NOTE

• If cabinet has a drawer, a 5-1/4”[3.2cm] depth clearance from the top of the countertop to the

top of the drawer (or other obstruction) in base cabinet is required. The drawer depth may

need to be shortened to avoid interfering with the regulator.

• 24” [61 cm] min. clearance if bottom of wood or metal cabinets is protected by not less than

1/4” [0.6cm] flame retardant millboard covered with not less than No. 28 MSG sheet steel

0.015” [0.04cm] stainless steel, or 0.024” [0.06 cm] aluminum or 0.020” [0.05 cm] copper.

30” [76.2cm] min. clearance between top of cooking platform and bottom of unprotected

wood or metal cabinet.

Figure 9.

Cutout Requirements (2/2)

LOCATION AND INSTALLATION

(continued)

MOBILE HOME INSTALLATION

The installation of this cooktop must conform to the Manufactured Home Construction and Safety Standards, Title 24 CFR, Part 3280 (formerly the Federal Standard for Mobile Home Construction and Safety;

Title 24 HUD part 280); or when such standard is not applicable, the Standard for Manufactured Home Installations (Manufactured Home Sites, Communities and Setups), ANSI A225.1 - latest edition, or with local codes.

In Canada, the installation of this cooktop must conform with the current standards CAN/ CSA-Z240 - latest edition, or with local codes.

The appliance should not be installed with a ventilation system that blows air downward toward the range. This type of ventilation system may cause ignition and combustion problems with the gas cooking appliance resulting in personal injury or unintended operation. See the VENTILATION REQUIREMENTS section of this manual for more details.

LOCATION AND INSTALLATION

(continued)

COUNTERTOP ADDITIONAL

Always consult the countertop manufacturer for specific instructions.

Ensure the countertop is square and level and ensure no structural members interfere with space requirements.

Prepare the cut-out according to the instructions (see cut-out dimensions).

Make sure the wall coverings, countertop and cabinets around the cooktop can withstand heat up to 200° F [93º C] .

CAUTION

EXCESSIVE WEIGHT HAZARD

Use two or more people to move and install cooktop.

Failure to do so can result in back or other injury.

CUT HAZARD

Beware of sharp edges. Use the polystyrene ends when carrying the product. Failure to use caution could result in minor injury or cuts.

Figure 10.

Tools Required

LOCATION AND INSTALLATION

(continued)

Step 1

Remove packaging materials and literature package from the cooktop before beginning installation.

Remove installation instructions from literature pack and read them carefully before you begin.

Step 2

Foam tape is provided to seal the cooktop edges to the countertop. Apply the provided foam tape to the underside of the cooktop edge.

Use tape around the entire cooktop perimeter.

Trim the tape ends so they meet closely.

MANUAL

GASKET

GAS CONVERSION KIT GAS CONNECTION KIT

PRESSURE REGULATOR

COOKTOP

GRATES

CARDBO

ARD

Figure 11.

Package Contents

Figure 12.

Apply Foam tape

Step 3

Insert the cooktop centered into the cutout opening.

Make sure the front edge of the counter top is parallel to the cooktop. Make final check that all required clearances are met.

Step 4

Four clamp brackets are provided with your unit.

After cooktop has been installed into the countertop, install the brackets on the burner box as shown in

Figure 14

Install the clamp brackets on the front and back of the burner box bottom (if the cabinet construction does not provide clearance for installing brackets at the front and back of the burner box, install the clamp brackets on the sides of the burner box).

Step A: place the clamping screws into brackets Step B: attach brackets by using the attachment screws on the selected location of burner box,

tighten screws just enough to hold brackets in place Step C: position brackets so that each clamp screw is in contact with the counter top bottom Step D: tighten attachment screws securely. Step E: check that the front edge of the cooktop is parallel to the front edge of the countertop

tighten the clamping screw against the countertop. DO NOT OVER TIGHTEN.

Figure 13.

Place Cooktop

Figure 14.

Install and Secure Clamps

LOCATION AND INSTALLATION

(continued)

GAS SUPPLY

The local gas authority or supplier should be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas (NG or LP). If it is a new installation, have the gas authorities or supplier check the meter size and piping to assure that the unit is supplied with the necessary amount of gas supply and pressure to operate the unit(s).

• Gas connections should be made by a qualified plumber, or your professional appliance installer.

• All appliances (NG or LP) must be fitted with an accessible upstream gas shutoff valve as a means of isolating the appliance for emergency shut off and for servicing.

• Make certain new piping and connections have been made in a clean manner and have been purged so that piping compound, chips, etc. will not clog regulators, valves, orifices, or burners. Use pipe joint compound / thread sealant approved for natural and LP gases.

PRECAUTIONS FOR SUPPLY TESTING

The appliance and its individual manual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi [3.5kPa].

The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of that system at test pressures equal to or less than 1/2psi [3.5 kPa].

NEVER CONNECT THE APPLIANCE TO AN UNREGULATED GAS SUPPLY.

If the line pressure supplying the appliance pressure regulator exceeds 14 inches W.C. (any gas), an external regulator must be installed in the gas line ahead of the appliance regulator to reduce the pressure to no more than 14 inches W.C. Failure to do this can result in malfunction and damage to the appliance.

GAS TYPE AND PRESSURE

Before proceeding, verify that the appliance is fitted for the type of fuel available. Connecting to an improper gas type will result in poor performance and increased risk of damage or injury. Gas type is shown on the rating label. If the appliance has been converted for an alternate fuel, that information should be next to the rating label or near the regulator.

The gas should be supplied to the appliance’s pressure regulator at line pressure between 6 and 14 inches of water column for NG, and between 11 and 14 inches of water column for LP.

Installation of this cooking appliance must be made in accordance with local codes. In the absence of local codes, this unit should be installed in accordance with the National Fuel Gas Code No.

Z223.1/ NFPA 54

, Natural Gas and Propane Installation code

CSA B149-1

, or Propane Storage and

Handling Code B149.2.

CONVERSION KITS

A conversion kit is provided with the cooktop. The conversion can only be performed by a qualified technician. In the event your Hestan appliance needs to be converted from NG to LP, or vice-versa, you will need to contact Hestan Customer Service to arrange a service call.

GAS CONNECTION

(CONTINUED)

GAS CONNECTION

After connecting, the installation must be checked for leaks. That procedure is on the following page.

Connect to gas supply using a minimum 1/2” inside diameter flexible (semi–rigid) stainless steel gas hose to prevent gas starvation. This hose should be no more than 36” [91.4 cm] in length, or as permitted by applicable codes. The included regulator must be installed between the shutoff valve and the appliance, and must be mounted so that its directional arrow (flow direction) points toward the gas manifold.

NEVER REUSE OLD HOSES WHEN INSTALLING THIS COOKTOP.

ANSI Z21.24/CSA 6.10 and ANSI Z21.75/CSA

6.27 codes require that a new gas appliance hose must be used for a new appliance, when moving an appliance to a new location, or as a result of damage.

Use the appropriate thread sealant on all NPT connections. Do not apply sealant to flare fittings.

NEVER TIGHTEN TO MORE THAN 35 ft lbs OF TORQUE.

Check alignment of valves after connecting the cooktop to the gas supply to be sure the manifold pipe has not been moved. A misalignment could cause the valve knob stem to rub on the control panel, resulting in a gas leak at the valve.

CAUTION

Do not attempt to attach the flexible hose directly to an external pipe thread.

Connection requires proper adapters to join the flex hose and the pipe fittings.

FOR MASSACHUSETTS INSTALLATIONS:

1. Shut-off valve must be a “T” handle gas cock.

2. Flexible gas hose must not be longer than 36 inch [91.4 cm].

3. Not approved for installation in a bedroom or a bathroom unless unit is direct vent.

MANIFOLD ENTRANCE

GASKET

FLARE ADAPTOR

*****

ADAPTOR

--- to

1/2" NPT

ELBOW

1/2" NPT

PIPE NIPPLE

1/2" NPT PIPE (STATIONARY SUPPLY PIPE)

NO APPLIANCE

MOUNTED BELOW

THIS COOKTOP

WALL OVEN MOUNTED

IN CABINETRY BELOW

THIS COOKTOP

GAS

SHUT-OFF

VALVE

GAS

SHUT-OFF

VALVE

FLEXIBLE

GAS HOSE

36” MAX

(91.4 cm) MAX

FLEXIBLE

FLARE

ADAPTOR

FLARE

ADAPTOR

FLARE

ADAPTOR

APPLIANCE PRESSURE

REGULATOR, SUPPLIED

(OBSERVE GAS FLOW

DIRECTION)

APPLIANCE

PRESSURE

REGULATOR,

SUPPLIED (OBSERVE

DIRECTIONALITY

OF GAS FLOW)

GAS HOSE

36” MAX

(91.4 cm) MAX

Figure 15.

Typical Methods Of Connecting Gas

GAS CONNECTION

(CONTINUED)

LEAK TESTING

GENERAL Although all gas connections on your Hestan appliance are leak tested at the factory prior to

shipment, a complete gas tightness check must be performed at the installation site due to possible movement in shipment, or excessive pressure unknowingly being applied to parts of the unit. Immediately check if the smell of gas is detected. Leak testing of the appliance shall be conducted according to these instructions:

BEFORE TESTING

• Do not smoke while leak testing.

• Never leak test with an open flame.

• Make a soap solution of one part liquid detergent and one part water for leak testing purposes.

• Apply the solution to the gas fittings and flex hose by using a spray bottle or a brush.

TO TEST

• Make sure all control knobs are in the “OFF” position.

• Apply the soap solution to all fittings and flex hose.

• Turn the gas supply on.

• Check all connections from the supply line up to regulator connection at the rear of the appliance.

• Soap bubbles will appear where a leak is present. If a leak is present, immediately turn off gas supply, tighten any leaking fittings, turn the gas supply back on, and recheck.

• If you cannot stop a gas leak, turn off the gas supply and call the dealer where you purchased your appliance.

• Do not use the appliance until all connections have been checked and do not leak.

TESTING APPLIANCE REGULATOR

When checking appliance regulator function, make certain that the correct pressure is supplied to the regulator. For natural gas supply, between 6 and 14 inches of water column. If converted for LP gas, between 11 and 14 inches.

To pressure test the regulator, select one of the side burners and connect to the orifice port, as follows.

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