Thermador PAALTKITGW Installation Manual

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) ............................................................ 16

Índice de materias (Español)............................................................ 29

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

Checklist ................................................................... 6

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

Checklist ...................................................................7

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

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

Disassembling the rangetop........................................... 9

Setting the STAR burner valve screws ............................ 9

Changing the broil orifice, on GAS ranges only............. 10

Changing the bake orifice, on GAS ranges only ............11

Checking for gas leaks.................................................... 14

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.

Reassembling the appliance ........................................... 14

Checking the flame and burner performance................. 14

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

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.

This kit is for converting Thermador appliances for operation at altitudes above 5,400 ft. This kit contains orifices for proper high altitude conversion for oven bake, broiler, and STAR

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 cannot be used to convert older models of ranges. This kit cannot be used to convert any other brand of appliance.

WARNING

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.

burners.

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. 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.

Page. 4

9 IMPORTANT SAFETY INSTRUCTIONS

READ AND SAVE THESE INSTRUCTIONS

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).

State of California Proposition 65 Warning: : WARNING

This product can expose you to chemicals including vinyl chloride, which is known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to

www.P65Warnings.ca.gov.

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.

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.

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.

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

• Adjustable wrench

• Soap and water mixture or leak-check solution

Parts included

Pro range natural gas high altitude kit for

cavity burners,

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

Qty.

Converting natural gas units above 5,400 ft. and up to 10,200 ft.

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

36'' and 48'' Pro Harmony

(PRGxxxWxH)

Main oven bake burner only 2.06 mm (206)

48'' Pro Grand

(PRGxxxWxG)

Auxiliary oven bake burner only 1.85 mm (185)

Checklist

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

36'' and 48'' Pro Harmony models (PRGxxxWxH)

Orifice no.

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

oven bake Orifice, 1.85 mm (185), 48'' Grand aux oven

bake

Pro range LP gas high altitude kit for STAR

and cavity burners,

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

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

oven broil

Qty.

Ù Step 1 Ù Step 2 Ù Step 3

Ù Step 4 Ù Step 5

48'' Pro Grand models (PRGxxxWxG)

Ù Step 1 Ù Step 2 Ù Step 3

Ù Step 4 Ù Step 5

Remove the oven door (page 11).

Remove the kick and front panels (page 13).

Change the main oven bake burner orifice to the 2.06 mm (206) orifice (page 11 – page 13).

Check the oven for gas leaks (page 14).

Reassemble the door, kick and front panels.

Remove the oven door (page 11).

Remove the kick and front panels (page 13).

Change the auxiliary oven bake burner orifice to the 1.85 mm (185) orifice (page 11 – page 13).

Check the oven for gas leaks (page 14).

Reassemble the door, kick and front panels.

Page. 6

Converting propane gas units

48'' Pro Harmony models (PR(G/L)48xWxH)

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

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

36'' and 48'' Pro Harmony

PR(L/D)xxxWxH(U/C)

All front STAR® burners only 1.26 mm (126) All rear STAR burners Remain unchanged

48'' Pro Harmony and 36'' Pro Grand

(PRL48xWxH and PRL36xWxG)

Main oven broil

• 48'' Pro Harmony (PRL48xWxH)

• 36'' Pro Grand (PRL36xWxG)

All other range models’ ovens and STAR burners

Checklist

Orifice no.

1.20 mm (120)

Remain unchanged

Ù Step 1

Ù Step 2

Ù Step 3 Ù Step 4 Ù Step 5

Ù Step 6

Ù Step 7

36'' Pro Grand models (PR(G/L)36xWxG)

Ù Step 1 Ù Step 2

Ù Step 3 Ù Step 4

Change only the front burner orifices to the

1.26 mm (126) orifices (page 8). Set the valve screws for the front STAR

burners only (page 9). Remove the oven door (page 11).

Remove the kick and front panels (page 13).

Change the main oven broil burner orifice to the 1.20 mm (120) orifice (page 10 – page 11).

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

Reassemble the rangetop, door, kick and front panels.

Remove the kick and front panels (page 13).

Change the broil burner orifice to the 1.20 mm (120) orifice (page 10 – page 11).

Check the oven for gas leaks (page 14).

Reassemble the door, kick and front panels.

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

36'' Pro Harmony models (PR(G/L/D)xxxWxH(U/C))

Ù Step 1

Ù Step 2

Ù Step 3 Ù Step 4

Change only the front burner orifices to the

1.26 mm (126) orifices (page 8). Set the valve screws for the front STAR

burners only (page 9). Check the rangetop for gas leaks (page 14).

Reassemble the rangetop.

Page. 7

Installation procedure

Changing the STAR® burner orifices

Only necessary for converting propane gas units from 10,000 ft. to 10,200 ft.

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

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.

36'' and 48'' Pro Harmony

PR(L/D)xxxWxH(U/C)

All front STAR All rear STAR burners Remain unchanged

To prepare the nut driver for the STAR burner orifice conversions

The foam tape helps to hold the orifice in the end of the nut driver so it will not fall inside the appliance during orifice removal or installation.

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

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

orifices, as shown below.

burners only

Orifice no.

1.26 mm (126)

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

orifice from the STAR burner’s jet holder.

To replace the rangetop STAR burner orifices

To remove the STAR burner orifices

1. Remove the rangetop grates and the burner caps.

2. Use a 16 mm hex head bit for burners labeled ‘D’ or ‘F’. Use a 9 mm hex head bit for burners labeled ‘B’ to remove the burner venturi from each burner base.

Page. 8

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

2. Replace orifices as indicated in the table.

All front STAR burners only 1.26 mm (126) 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.

Disassembling the rangetop

Only necessary if an orifice is dropped

Setting the STAR® burner valve screws

inside the rangetop

9 CAUTION

Shut off the gas supply to the appliance prior to disconnecting the electrical power.

To disassemble the rangetop

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

backguard.

Only necessary for converting propane gas units from 10,000 ft to 10,200 ft.

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.

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

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

a. Burner base b. Electrode c. Igniter housing d. Igniter wire

5. Carefully remove each burner pedestal.

6. Remove the spill trays by rotating 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 the adjacent spill tray.

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

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

Page. 9

4. Adjust the valve screw by turning the valve screw about an 1/8 size. Turn the screw counter-clockwise to make the simmer flame larger. Adjust the valve screw as little as required to reach satisfactory simmer results. Due to normal fluctuations in gas pressure, over-adjustment of valve screw may affect flame stability.

5. Perform a gas leak test of each orifice and associated supply tube fittings. See “Checking for gas leaks” on page 14. Leak-checking should occur after the orifice conversion is complete, and before the burner is reassembled and tested.

turn clockwise to reduce simmer flame

Changing the broil orifice, on GAS ranges only

Only necessary for converting propane gas units from 10,000 ft to 10,200 ft.

9 CAUTION

Removing the backguard assembly

1. Use a T-20 torx screwdriver to remove the screws from the front and rear panel of the backguard assembly.

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.

NOTE: Dual Fuel ranges have electric ovens and do not have a broil orifice.

Change only the following oven broil orifices. All other orifices shall remain the same.

48'' Pro Harmony and 36'' Pro Grand

(PRL48xWxH and PRL36xWxG)

Main oven broil

• 48'' Pro Harmony

• 36'' Pro Grand

Orifice no.

1.20 mm (120)

2. Carefully lift the backguard assembly from the range.

Page. 10

Changing the broil burner orifice

Changing the bake orifice, on

1. Remove the 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.

2. Replace the orifices as indicated in the table.

48'' Pro Harmony and 36'' Pro Grand

(PRL48xWxH and PRL36xWxG)

Orifice no.

GAS ranges only

Only necessary for converting natural gas units above 5,400 ft. and up to 10,200 ft.

NOTE: Dual Fuel ranges have electric ovens and do not have a bake orifice.

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

36'' and 48'' Pro Harmony

(PRGxxxWxH)

Main oven bake burner only 2.06 mm (206)

48'' Pro Grand

(PRGxxxWxG)

Auxiliary oven bake burner only 1.85 mm (185)

Removing the oven door

Orifice no.

Main oven broil

• 48'' Pro Harmony

• 36'' Pro Grand

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 the “Check for gas leaks” section of these instructions.

1.20 mm (120)

9 CAUTION

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

• 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.

Page. 11

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.

Reinstalling the oven door

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.

Page. 12

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

Removing the kick and front panels

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

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

IMPORTANT: DO NOT bend the bake burner tube or shutter. Ensure that the bake orifice is aligned to the center of the burner tube inlet.

2. Hand twist the orifice elbow (a) while restraining the bake orifice (b) from rotation using an adjustable

wrench.

a. Orifice elbow b. Bake orifice

3. Replace the orifices as indicated in the table and reattach the gas line.

Changing the bake burner orifice

To change the bake burner orifice

1. Remove the bake gas line using a 13/16'' box end wrench, while restraining the elbow fitting from

rotation using an adjustable wrench.

36'' and 48'' Pro Harmony

(PRGxxxWxH)

Main oven bake burner only 2.06 mm (206)

48'' Pro Grand (PRG48xWxG) Orifice no.

Auxiliary oven bake burner only 1.85 mm (185)

4. Perform a gas leak check of the orifice and associated supply tube fittings, per the “Check for gas leaks” section of these instructions.

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

Orifice no.

Page. 13

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