Thermador PAALTKITGW, PAALTKITHW, 12025444 Installation Guide

THERMADOR.COM

Installation

INSTRUCTIONS

Pro Harmony® and Pro Grand® High Altitude Conversion Kit

THERMADOR.COM

Installation

INSTRUCTIONS

Table of contents (English) ................................................................ 3

Table de matières (Français) ............................................................ 18

Índice de materias (Español)............................................................ 34

Models | Modèles | Modelos:

PAALTKITGW PAALTKITHW 12025444

Pro Harmony® and Pro Grand® High Altitude Conversion Kit

Table of

Safety

CONTENTS

Safety ...................................................................................... 4

Important safety instructions ..........................................4

High altitude instructions........................................................ 6

Before you begin ............................................................ 6

Natural gas units above 5,400 ft. and up to 10,200 ft.... 6

PAALTKITHW checklist............................................. 6

PAALTKITGW checklist............................................. 6

Propane gas units from 10,000 ft. to 10,200 ft............... 7

12025444 checklist................................................... 7

Installation procedure.............................................................8

Changing the STAR® burner orifices ............................. 8

Disassembling the rangetop........................................... 8

Changing the broil orifice...............................................9

Changing the bake orifice ..............................................10

Checking for gas leaks.................................................... 13

DEFINITIONS

9 WARNING

This indicates that death or serious injuries may occur as a result of non-observance of this warning.

9 CAUTION

This indicates that minor or moderate injuries may occur as a result of non-observance of this warning.

NOTICE: This indicates that damage to the appliance or property may occur as a result of non-compliance with this advisory.

Note: This alerts you to important information and/or tips.

Checking the flame and burner performance................. 15

Setting the STAR

Support, accessories, and parts..................................back page

burner valve screws.......................... 16

This THERMADOR® appliance is made by

BSH Home Appliances Corporation

1901 Main Street, Suite 600

Irvine, CA 92614

Questions?

1-800-735-4328

www.thermador.com

We look forward to hearing from you!

Page. 3

Safety

9 IMPORTANT SAFETY INSTRUCTIONS

READ AND SAVE THESE INSTRUCTIONS

Please read carefully

Save the original gas parts for possible conversion back in the future.

Important: Only a qualified service technician or installer should make this conversion.

Installer: Please leave these instructions with this unit for the owner.

Owner: Please retain these instructions for future reference.

WARNING

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

-- 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

• DO NOT try to light any appliance.

• DO NOT touch any electrical switch.

• DO NOT use any phone in your

building.

• Immediately call your gas supplier

from a neighbor’s phone. Follow the gas supplier’s instructions.

• 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.

These instructions advise you at what elevations and which models you will need to convert your appliance for proper operation at high altitude regions. It further instructs you which parts of the appliance will need to convert to high altitudes.

This kit is for converting Thermador appliances. This kit cannot be used to convert older models of ranges. This kit cannot be used to convert any other brand of appliance.

WARNING

This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction. In any case, the installation of this conversion kit must conform with local codes or, in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or, in Canada, the Natural Gas and Propane Installation Code, CSA B149, latest edition. If the information in these instructions is not followed exactly, a fire, explosion or production of carbon monoxide may result causing property damage, personal injury, or loss of life. The qualified service agency is responsible for the proper installation of this kit. The installation is not proper and complete until the operation of the converted appliance is checked as specified in the manufacturer’s instructions supplied with the kit.

WARNING

Never Operate the Top Surface Cooking Section of this Appliance Unattended

• Failure to follow this warning statement could result in fire, explosion, or burn hazard that could cause property damage, personal injury, or death.

• If a fire should occur, keep away from the appliance and immediately call your fire department. DO NOT ATTEMPT TO EXTINGUISH AN OIL/GREASE FIRE WITH WATER.

Page. 4

9 IMPORTANT SAFETY INSTRUCTIONS

READ AND SAVE THESE INSTRUCTIONS

For Massachusetts installations

1. Installation must be performed by a qualified or licensed contractor, plumber, or gas fitter qualified or licensed by the state, province or region.

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

3. Flexible gas connector must not be longer than 36 inches.

The following must be met when testing supply piping system:

• The appliance and its individual shut-off valve must be disconnected from the gas supply piping system at test pressures in excess of 1/2 psig (3.5 kPa).

• The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/ 2 psig (3.5 kPa).

Proposition 65 Warning

This product may contain a chemical known to the State of California, which can cause cancer or reproductive harm. Therefore, the packaging of your product may bear the following label as required by California:

State of California Proposition 65 Warning:

: WARNING

Cancer and Reproductive Harm -

www.P65Warnings.ca.gov

To the service agent

It is important that you know the following BEFORE you begin the conversion of the appliance.

• Confirm that the gas supply system is available and ready to use. This is particularly important for new construction.

• Verify the type of gas supplied to the location. Ensure that the appliance is connected to the type of gas for which it is certified.

• You must plan for sufficient time and resources to perform the conversion process properly and completely before leaving the job site. Every step described in these instructions must be performed to safely convert the appliance for proper operation at high altitudes. INCOMPLETE OR INADEQUATE

CONVERSION OF THE APPLIANCE CAN CREATE A SAFETY HAZARD.

Gas and dual fuel ranges converted for propane (LP) gas and high altitude

The appliance must first be converted for use with propane (LP) gas before it can be converted for use at high altitude. It is required that a a qualified service technician install the propane (LP) conversion kit and the high altitude kit.

WARNING NEVER leave the gas conversion partially completed. If

the appliance is operated while the gas conversion is incomplete, high levels of carbon monoxide may be emitted, or a fire or explosion may occur.

Page. 5

High altitude instructions

Before you begin

9 CAUTION

Before proceeding with the conversion, shut off the gas supply to the appliance prior to disconnecting the electrical power. Disconnect the appliance from electrical power by unplugging the electrical cord from its receptacle or by disconnecting power at the circuit breaker box.

Tools needed

• T-20 torx driver

• 7/16'' box end wrench

• 13/16'' box end wrench

• 7 mm or a 9/32'' socket

• 1/4'' nut driver

• 16 mm hex bit or 5/8'' hex bit or 16 mm Allen wrench

• T-30 torx driver

• 1/2'' offset box end wrench

• 9/32'' open end wrench

• 7/8'' socket or 7/8'' open end wrench

• Adjustable wrench

• Soap and water mixture or leak-check solution

Converting natural gas units

Change only the following oven bake burner. All other burners’ orifices shall remain the same.

Checklist for 36'' and 48'' PRO HARMONY

Ù Step 1 Ù Step 2 Ù Step 3

Ù Step 4 Ù Step 5

Ù Step 6

Ù Step 7

Remove the oven door (page 11).

Remove the kick and front panels (page 12).

Change the main oven bake burner orifice to the 2.06 mm (206) orifice (page 12).

Reassemble the door (page 11).

Check the main oven bake burner for gas leaks (page 14).

Check flame and burner performance of the main oven bake burner (page 17).

Reassemble the kick and front panels (page 12).

PAALTKITGW Pro Grand checklist

For altitudes above 5,400 ft. and up to 10,200 ft. on 48'' PRO GRAND natural gas ranges only

Parts included Qty.

Screwdriver, 1/8'' x 0.20'' 1 Orifice, 1.85 mm (185), 48'' Pro Grand, auxiliary

oven bake burner only

above 5,400 ft. and up to 10,200 ft.

Each of the following steps must be completed correctly for the appliance to function properly. Check off each step as it is finished.

PAALTKITHW Pro Harmony checklist

For altitudes above 5,400 ft. and up to 10,200 ft. on 36'' and 48'' PRO HARMONY natural gas ranges only

Parts included Qty.

Screwdriver, 1/8'' x 0.20'' 1 Orifice, 2.06 mm (206), 36'' and 48'' Pro

Harmony, main oven bake burner only

Change only the following oven bake burner. All other burners’ orifices shall remain the same.

Checklist for 48'' PRO GRAND

Ù Step 1 Ù Step 2 Ù Step 3

Ù Step 4 Ù Step 5

Ù Step 6

Ù Step 7

Remove the oven door (page 11).

Remove the kick and front panels (page 12).

Change the auxiliary oven bake burner orifice to the 1.85 mm (185) orifice (page 13).

Reassemble the door (page 11).

Check the auxiliary oven bake burner for gas leaks (page 14).

Check flame and burner performance of the auxiliary oven bake burner (page 17).

Reassemble the kick and front panels (page 12).

Page. 6

Converting propane gas units

Checklist for 48'' PRO HARMONY

from 10,000 ft. to 10,200 ft.

Each of the following steps must be completed correctly for the appliance to function properly. Check off each step as it is finished.

12025444 Pro Harmony and Pro Grand propane gas checklist

For altitudes from 10,000 ft. to 10,200 ft. on 36'' PRO HARMONY LP converted ranges

Change only the following STAR burners shall remain the same.

Parts included Qty.

Screwdriver, 1/8'' x 0.20'' 1 Orifice, 1.26 mm (126), front STAR burner 3

Checklist for 36'' PRO HARMONY

Ù Step 1 Ù Step 2

Ù Step 3 Ù Step 4

Ù Step 5

For altitudes from 10,000 ft. to 10,200 ft. on 48'' PRO HARMONY LP converted ranges

Disassemble the rangetop (page 8).

Change only the front burner orifices to the

1.26 mm (126) orifices (page 8). Check the rangetop for gas leaks (page 13).

Reassemble the rangetop and check STAR burner flame performance (page 15).

Set the valve screws for the front STAR burners only (page 16).

burner orifices. All other

Ù Step 1 Ù Step 2

Ù Step 3 Ù Step 4

Ù Step 5

Ù Step 6

Ù Step 7

Ù Step 8 Ù Step 9

For altitudes from 10,000 ft. to 10,200 ft. on 36'' PRO GRAND LP gas converted ranges

Change only the following oven orifice. All other burners shall remain the same.

Screwdriver, 1/8'' x 0.20'' 1 Orifice, 1.20 mm (120), main oven broil burner 1

Checklist for 36'' PRO GRAND

Ù Step 1 Ù Step 2

Ù Step 3

Disassemble the rangetop (page 9).

Change only the front burner orifices to the

1.26 mm (126) orifices (page 8). Remove the backguard (page 9).

Change the main oven broil burner orifice to the 1.20 mm (120) orifice (page 9).

Check the oven and rangetop for gas leaks (page 14).

Reassemble the rangetop and check STAR burner flame performance (page 15).

Set the valve screws for the front STAR burners only (page 16).

Check the broil flame performance (page 17).

Reassemble the backguard (page 9).

Parts included Qty.

Remove the backguard (page 9).

Change the main oven broil burner orifice to the 1.20 mm (120) orifice (page 9).

Check the oven for gas leaks (page 14).

Change only the following STAR burner and oven orifices. All other burners shall remain the same.

Parts included Qty.

Screwdriver, 1/8'' x 0.20'' 1 Orifice, 1.20 mm (120), main oven broil burner 1 Orifice, 1.26 mm (126), front STAR burner 3

Ù Step 4 Ù Step 5

Check the broil flame performance (page 17).

Reassemble the backguard (page 9).

Page. 7

Installation procedure

Changing the STAR® burner orifices for converting propane gas units from 10,000 ft. to 10,200 ft. (12025444 kits)

Disassembling the rangetop

9 CAUTION

Before proceeding, shut off the gas supply to the appliance prior to disconnecting the electrical power. Disconnect the appliance from electrical power by unplugging the electrical cord from its receptacle or by disconnecting power at the circuit breaker box.

To disassemble the rangetop

1. Remove the rangetop grates and the burner caps.

2. To facilitate the removal of the spill tray, remove the T20 torx screws in the front face of the island trim or backguard.

3. Use a 16 mm hex head bit or Allen wrench to remove the burner venturi from each burner base.

a. Grate b. Burner cap c. Venturi d. Burner base e. Electrode f. Burner pedestal g. Spill tray h. Heat shield i. Igniter housing j. Igniter wire

a. Hex head bit or Allen wrench b. Burner venturi

TIP: If a 16 mm hex head bit is not readily available, a 5/8'' hex bit can be selected. Alternatively, a bolt with 5/8'' head either “double-nutted” or tightened into the chuck of a power driver can be used.

4. Disconnect the igniter. Carefully pull up on the burner base.

5. Remove the screw securing the burner pedestal with a T-30 torx driver. Carefully remove each burner pedestal.

6. Remove the spill trays by pivoting the trays up and out the back.

7. Remove the heat shield on some models. Some models have a double-width shield that extends under adjacent spill tray.

Page. 8

Preparing for STAR® burner orifice

conversion

To prepare the 7 mm, 9/32'' socket, or ¼'' nut driver for STAR burner orifice replacement

1. Trim a small piece of the foam tape provided with this kit to about 1/4 – 1/2'' (6 – 12 mm).

2. Place foam tape over the edge of a 7 mm or a 9/32'' socket, or with 1/4'' nut driver used to replace the burner orifices, as shown below.

• The foam tape helps to retain the orifice in the

end of the nut driver so it will not fall inside the appliance during orifice removal or installation.

3. Locate the proper STAR burner orifices included with the kit. Orifices are stamped with the orifice diameter size on the side.

4. Replace orifices as indicated in the table below. Ensure the orifice is completely seated and tight to the jet holder to avoid possible gas leaks.

36'' and 48'' Pro Harmony, LP units Orifice no.

All front STAR All rear STAR burners remain unchanged

NOTE: All of the replacement orifices in the conversion kit have straight threads (not pipe threads) and do not require thread sealing compound.

burners only

1.26 mm (126)

Changing the broil orifice, for converting propane (LP) gas units from 10,000 ft to 10,200

To replace the front STAR burner orifices

1. With the foam tape wrapped nut driver, reach down through the jet holders and remove the gas orifice

from the STAR burner’s jet holder.

2. Label each of the removed orifices, noting from which burner they were removed, in the event the appliance is converted back.

For your convenience, note the orifice sizes and locations in the following table.

ft. only (12025444 kits)

9 CAUTION

After the replacement of the broiler orifice, and before reassembly of the back panel and backguard to the range, perform a brief gas leakage check of the orifice and associated fittings, per the “Checking for gas leaks” section of these instructions.

Removing the backguard assembly

1. Move the range out of its installed position to gain full access to the rear panel of the backguard assembly and to the broil burners' orifices.

2. Use a T-20 torx screwdriver to remove the screws from the front of the backguard assembly.

Burner location Orifice size

Left front Center front Right front All rear burners remain unchanged

Page. 9

3. Use a T-20 torx screwdriver to remove the screws from the back rear panel of the backguard assembly.

4. Carefully lift the backguard assembly from the range.

2. Replace the orifices as indicated in the table.

48'' Pro Harmony and 36'' Pro

Grand, LP units

Main oven broil 1.20 mm (120) Auxiliary oven broil remain unchanged

NOTE: The replacement broil orifices have straight threads (not tapered threads) and DO NOT require thread sealing compound.

3. Perform a gas leakage check of the orifice and associated supply tube fittings, per “Gas leak checking the broil orifice” on page 14.

Orifice no.

Changing the bake orifice, for converting natural gas units above 5,400 ft. and up to 10,200 ft. only (PAALTKITHW

Changing the broil burner orifice

1. Remove broil orifice using a 7/16'' box end wrench, while restraining the elbow fitting from rotation using a small adjustable wrench.

IMPORTANT: DO NOT bend the broil burner orifice bracket. Ensure that the broiler orifice is aligned to the center of the burner tube inlet.

and PAALTKITGW kits)

Removing the oven door

9 CAUTION

• USE CAUTION WHEN REMOVING THE DOOR. THE DOOR IS VERY HEAVY.

• Make sure oven is cool and power to the oven has been turned off before removing the door. Failure to do so could result in electrical shock or burns.

• The oven door is heavy and fragile. Use both hands to remove or replace the door.

• Failure to grasp the oven door firmly and properly could result in personal injury and product damage.

• With the door off, never release the levers and try to close the hinges. Without the weight of the door, the powerful springs will snap the hinges closed with great force.

To gain access to the bake burner orifices, you will need to remove the oven door, kick panel, and the bottom front panel, if applicable.

Page. 10

To remove the oven door

Reinstalling the oven door before leak

1. Open the door fully. Flip the hinge clips down for both sides of the door. A screwdriver may be required to carefully pry the clip back.

2. Close the door gently until it stops against the hinge clips. The open hinge clips will hold the door open at a slight angle, about 30°, from the closed position.

3. Grasp the door firmly on the ends of the door. Lift the door up and out. There will be some spring resistance to overcome.

testing the broil or bake burners

1. Hold the door firmly in both hands.

2. Hold the door at a 30° angle from the closed position. Insert hinges centered evenly into the hinge slots. The hinges will securely hook into the slots when properly installed. DO NOT force, bend or twist the door.

3. Open door fully to expose hinges, levers, and slots.

4. Flip the hinge forward until seated on the bracket. A screwdriver may be required to carefully push the clip back.

4. Place the door in a safe and stable location.

5. Close and open the door slowly to ensure it is correctly and securely in place.

Page. 11

Removing the kick and front panels

a e f

1. Remove the kick panel screws using a T-20 torx screwdriver.

2. Remove the front panel screws using a T-20 torx screwdriver.

a. Anti-rotation bracket b. Bake gas line c. Elbow fitting d. Shutter e. Bake burner tube

mounting bracket

1. Remove the bake gas line using a 13/16'' box end wrench.

2. Remove the two screws from the bake burner tube mounting bracket with a T-20 torx driver.

f. Bake burner tube

Changing the main oven bake burner orifice

IMPORTANT:

• Do not bend the bake burner tube.

• Do not bend the bake burner gas tube.

• Do not modify the shutter opening. The air shutter should remain fully open.

• Do not remove the anti-rotation bracket when performing the orifice change. This bracket is critical to the alignment of the bake burner tube with the burner orifice. After the orifice replacement, this bracket will facilitate the burner tube’s realignment.

3. Insert a 1/2'' offset wrench into the shutter opening to restrain the bake orifice while hand twisting the orifice elbow counterclockwise.

4. Replace the orifice as indicated in the table.

36'' and 48'' Pro Harmony Orifice no.

Main oven bake burner only 2.06 mm (206)

5. Ensure that the bake orifice is aligned to the center of the burner tube inlet. Reinstall the bake burner tube beneath the oven. If necessary, use a flashlight to aid in seeing the locating slot where the burner tube sits at the backside of the burner cavity.

6. Slide the elbow fitting back into the anti-rotation bracket. Reattach the two bake burner mounting bracket screws and tighten the gas line.

7. Perform a gas leakage check of the orifice and associated supply tube fittings per “Checking for gas leaks” on page 13.

Page. 12

Changing the auxiliary oven bake burner

orifice

a. Auxiliary bake burner

mounting bracket

c. Elbow fitting d. Bake burner tube

IMPORTANT:

• Do not bend the bake burner tube.

• Do not bend the bake burner gas tube.

• Do not modify the shutter opening. The air shutter should remain fully open.

b. Aux oven bake gas

line

Checking for gas leaks

9 WARNING

DO NOT use a flame of any kind to check for gas

leaks.

9 CAUTION

DO NOT spray water solution onto exposed electrical

components. If solution does drip onto electrical components, shut the power off before wiping off the electronics.

9 CAUTION

Ensure that the STAR burner igniter wire terminals do not touch the chassis metal, or any metal part, to prevent sparking. Do not touch the igniter wires while the burner is turned on to avoid being shocked.

Leak testing should occur after the orifices are replaced and before the appliance is fully reassembled. However, the doors of the appliance must also be installed and closed in order to leak check the broil and bake burners.

Leak testing of the appliance shall be conducted according to the following instructions.

1. Remove the two screws from the auxiliary bake burner mounting bracket with a T-20 torx driver. Pull the bracket and gas line carefully towards you.

NOTE: It is not necessary to loosen the auxiliary oven bake gas line.

2. With an adjustable wrench, restrain the elbow fitting. With a 1/2'' offset wrench, unscrew the auxiliary bake burner orifice.

3. Replace the orifice as indicated in the table.

48'' Pro Grand Orifice no.

Auxiliary oven bake burner only 1.85 mm (185)

NOTE: The replacement bake orifices have straight threads (not tapered threads) and DO NOT require thread sealing compound.

4. Before reattaching the auxiliary bake burner mounting bracket, perform a gas leakage check of the orifice and associated supply tube fittings per “Gas leak checking the bake orifice” on page 14.

Gas leak checking the rangetop STAR® burners

To leak check the rangetop’s STAR burners

1. Make sure that the orifices have been tightened and that all valves and controls are in the OFF position.

2. Turn on electric and gas supplies.

3. Spray a generous amount of soap and water mixture—or other solution designed for checking gas leaks—on the threaded junction at the base of the orifice, the elbow fitting, and gas tube compression nut. (A 25% dishwashing liquid to water mixture is effective for this.) Avoid spraying electrical components.

Page. 13

4. Turn the corresponding STAR burner knob to HI while firmly blocking the STAR burner's orifice hole with a soft rubber pencil eraser, your finger, or something similar.

5. Monitor the base of the orifice junction, elbow fitting, and compression nut to see if bubbles are forming anywhere around the connections.

• Bubbles forming are indications of gas leaks.

6. If appliance leaks, repair all gas leaks immediately. Do not over-torque the junctions, orifices or nuts, or bend the gas tubes.

7. Repeat for all STAR burners.

Gas leak checking the broil orifice

To leak check the broil burner orifice

1. Spray a generous amount of soap and water mixture—or other solution designed for checking gas leaks—on the threaded junction at the base of the orifice, the elbow fitting, and gas tube compression nut. (A 25% dishwashing liquid to water mixture is effective for this.) Avoid spraying electrical components.

2. Turn the mode knob and the oven temperature knob to BROIL while blocking the broil orifice hole with a soft pencil eraser, your finger, or something similar.

• There will be a delay of approximately 45 to 90

seconds as the safety valve coil heats to release the valve’s actuator. A single pop noise can usually be heard as the broiler’s safety valve opens.

3. Monitor the base of the orifice junction, elbow fitting, and compression nut to see if bubbles are forming anywhere around the connections.

• Bubbles forming are indications of gas leaks.

4. If appliance leaks, repair all gas leaks immediately. Do not over-torque the junctions, orifices or nuts, or bend the gas tubes.

5. If applicable, repeat for the auxiliary broil orifice.

Gas leak checking the bake orifice

To leak check the oven bake burner orifice

2. Turn the mode knob to BAKE and the oven temperature knob to any setting while blocking the bake orifice hole with your finger.

• There will be a delay of approximately 45 to 90

seconds as the safety valve coil heats to release the valve’s actuator. A single pop noise can usually be heard as the broiler’s safety valve opens.

3. Monitor the base of the orifice junction, elbow fitting, and compression nut to see if bubbles are forming anywhere around the connections.

• Bubbles forming are indications of gas leaks.

4. If appliance leaks, repair all gas leaks immediately. Do not over-torque the junctions, orifices or nuts, or bend the gas tubes.

5. If applicable, repeat for the auxiliary bake orifice.

6. If the appliance has been satisfactorily leak checked, turn off the gas and electric supplies. Reinstall the auxiliary bake burner mounting bracket, if applicable, and continue to “Checking the flame and burner performance”.

Page. 14

Checking the flame and burner

aaa

Checking the STAR burner ignition and flame

performance

Checking the STAR® burner performance

9 WARNING

When cooking with the STAR burners, the burner flame size should be adjusted so it does not extend beyond the edge of the cooking utensil. This instruction is based on safety considerations.

To observe the burner flames, it may be necessary to turn off lights or close window blinds to darken the room for easier viewing of the flame.

Reassemble the rangetop as follows:

a. Grate b. Burner cap c. Venturi d. Burner base e. Electrode

1. Push in the burner control knob and turn it to “HI”.

• The igniter electrode and spark module will

produce a clicking sound. Once the air has been purged from the supply lines, the burner should light within four seconds.

• The flames should be stable, with no excessive

noise. The inner cones of the individual flames should be defined and separate from each other. Portions of the flame, along the burner, should not exhibit excessive or continuous indications of

“lifting” or “lazy flame”.

a. Dark blue b. Secondary cone c. Light blue d. Primary cone

f. Burner pedestal g. Spill tray h. Heat shield i. Igniter housing j. Igniter wire

TIP: Use the burner venturi as a centering guide when remounting the burner pedestals. If the pedestals are centered, the venturi will slide in and out easily after the T30 torx head screw has been secured. If the pedestals are not centered properly, loosen the mounting screw and recenter the burner until the venturi slides freely.

NOTE: It is normal for slight yellow tipping of the flames to appear after a few minutes of operation using Propane (LP) gas. Orange-colored streaks in the flame are produced from burning airborne debris; this is normal during initial start up and should dissipate within a few

minutes of operation.

Yellow flames:

Further adjustment is required.

Yellow tips on outer cones:

Normal for LP gas

Soft blue flames:

Normal for natural gas

Page. 15

5. Adjust the burner’s control valve to LO to see that the

Star

flame continues to wrap around the burner. Blow out the flame, or use a quick fan motion from a writing tablet or piece of cardboard to extinguish the flame, and then observe the burner’s ability to reignite and wrap around (also called “carry-over”) the burner within several seconds. This flame “carry-over” is essential for proper burner ignition and re-ignition.

6. Test re-ignition of the XLO and observe the carry-over of the small simmer flames as the XLO system cycles the burners on and off.

• If the low flame performance is not acceptable it

may be necessary to readjust the valve screw for a

STAR

burner that does not have sufficient carryover of the low flame. Turn the valve screw very slightly counter-clockwise until carry-over of the flame is acceptable. (See “Setting the STAR® burner valve screws” on page 16.)

• If the burner flame is uneven, flutters, makes excessive noise, or lifts, some of the slots in the burner base may be blocked with food spillage or other debris.

• Clogged slots can be cleared using a straightened paper clip, needle, or similar object. Hard-toremove, encrusted food or debris can sometimes be removed using a steel wool pad or fine wire brush.

• Burner flames that are “lazy”, with excessivelylong flames, can be created by an incorrectly fitted burner cap—from which many of the outer mantles of the individual flames will tend to “coalesce” or blend together. Verify that the burner cap is seated properly on its burner base. The cap should fit reasonably flat when correctly-

positioned on the base and not rock significantly.

Setting the STAR® burner valve screws

A flat-head screwdriver with an 1/8" [3.0 mm] wide, .020" [0.50 mm] thickness tip (included) is used to adjust the valve screws.

To set the burner valve screws

1. Remove the knob from the valve stem by slowly pulling knob straight out, away from the control panel.

2. Remove the bezel-mounting screw located to the right of the valve stem, using a T-20 torx screwdriver.

Correct burner cap Incorrect burner cap

7. Repeat the ignition and flame test procedures for each rangetop STAR burner.

Page. 16

3. Insert included 1/8'' flat-blade screwdriver into the hole of the bezel mounting screw. Access to the valve screws through the clearance hole in the spark module. You should feel the engagement of the screwdriver and the valve screw.

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