Thermador PALPKITGW5 Installation manual

Installation

INSTRUCTIONS

Pro Harmony®, Pro Grand®, and Pro Rangetop Propane (LP) Conversion Kit

THERMADOR.COM

Installation

INSTRUCTIONS

Pro Harmony®, Pro Grand®, and Pro Rangetop Propane (LP) Conversion Kit

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

Table de matières (Français)............................................................ 24

Índice de materias (Español)............................................................ 46

Models | Modèles | Modelos:

PALPKITHW PALPKITHW5 PALPKITGW PALPKITGW5 PALPKITDGW PALPKITGGW

THERMADOR.COM

Table of

Safety

CONTENTS

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

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

Propane (LP) gas conversion instructions ............................... 6

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

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

Installation procedure............................................................. 9

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

Converting the regulator to LP....................................... 10

Changing the STAR® burner orifices ............................. 10

Propane (LP) burner orifice conversion tables................ 12

Changing the broil orifice, on GAS ranges only.............15

Changing the bake orifice, on GAS ranges only ............18

Checking for gas leaks.................................................... 19

Checking the flame and burner performance................. 20

Setting the STAR burner valve screws ............................ 22

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.

Placing the conversion label ........................................... 23

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 with propane (LP) gas. This kit contains orifices for proper LP conversion for oven bake, broiler, and top surface STAR

This kit is used to convert select models of Pro Rangetop, Pro Harmony, and Pro Grand ranges to propane (LP) gas usage. This kit cannot be used to convert older models of rangetops or ranges. This kit cannot be used to convert any other brand of appliance.

WARNING

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. 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).

CAUTION

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 (3.5 kPa) from the propane gas tank regulator.

To convert the appliance back for use with natural gas, follow these instructions exactly, but replacing the propane gas orifices with the original natural gas ones. Carefully match their correspondent burners as previously marked and labeled.

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 with propane (LP) gas. INCOMPLETE OR INADEQUATE

CONVERSION OF THE APPLIANCE CAN CREATE A SAFETY HAZARD.

The minimum propane (LP) gas supply pressure for the checking of the gas appliance pressure regulator, when converted for use with propane gas, must be between 11 inches water column (2.7 kPa) and 14 inches water column (3.5 kPa). Please refer to page 10 on to how to properly convert the gas pressure regulator for use with propane (LP) gas.

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, causing property damage, personal injury, or death.

Save the original natural gas orifices removed from the appliance for future use. Make sure that you carefully mark and label these orifices, indicating the correspondent burner from which they were removed.

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

Page. 5

Propane (LP) gas conversion 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 mm Allen wrench or 9 mm hex bit

• 9/32'' open end wrench

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

• Adjustable wrench

• Soap and water mixture or leak-check solution

LP gas kit parts included

Gas Pro Harmony ranges with 5 burners

(PRG305WH)

Conversion label 1 Foam tape, 1'' piece 1 Screwdriver, 1/8'' x 0.20'' 1 Orifice, 0.73 mm (73) 2 Orifice, 0.90 mm (90) 1 Orifice, 1.05 mm (105) 1 Orifice, 1.15 mm (115) 1 Orifice, 1.34 mm (134), main oven bake 1 Orifice, 1.25 mm (125), main oven broil 1

Qty.

Dual Fuel Pro Harmony ranges and Pro

Rangetop with 5 burners

(PRD305WH(U/C) or PCG305W)

Conversion label 1 Foam tape, 1'' piece 1 Screwdriver, 1/8'' x 0.20'' 1 Orifice, 0.73 mm (73) 2 Orifice, 0.90 mm (90) 1 Orifice, 1.05 mm (105) 1 Orifice, 1.15 mm (115) 1

Dual Fuel Pro Harmony ranges and Pro

Rangetop with 4 or 6 burners

Conversion label 1 Foam tape, 1'' piece 1 Screwdriver, 1/8'' x 0.20'' 1 Orifice, 1.05 mm (105) 3 Orifice, 1.15 mm (115) 3

Gas Pro Harmony ranges with 4 or 6 burners Qty.

Conversion label 1 Foam tape, 1'' piece 1 Screwdriver, 1/8'' x 0.20'' 1 Orifice, 1.05 mm (105) 3 Orifice, 1.15 mm (115) 3 Orifice, 1.34 mm (134), main oven bake 1 Orifice, 1.13 mm (113), aux oven bake 1 Orifice, 1.25 mm (125), main oven broil 1 Orifice, 0.75 mm (75), aux oven broil 1

Dual Fuel Pro Grand ranges with 4 or 6

burners

Conversion label 1 Foam tape, 1'' piece 1 Screwdriver, 1/8'' x 0.20'' 1 Orifice, 1.05 mm (105) 3

Qty.

Page. 6

Orifice, 1.15 mm (115) 2 Orifice, 1.26 mm (126) 1

Gas Pro Grand ranges with 4 or 6 burners Qty.

Pro Harmony gas models

Conversion label 1 Foam tape, 1'' piece 1 Screwdriver, 1/8'' x 0.20'' 1 Orifice, 1.05 mm (105) 3 Orifice, 1.15 mm (115) 2 Orifice, 1.26 mm (126) 1 Orifice, 1.46 mm (146), main oven bake 1 Orifice, 1.13 mm (113), aux oven bake 1 Orifice, 1.25 mm (125), main oven broil 1 Orifice, 0.813 mm (813) or “67”, aux oven broil* 1

*This orifice is stamped “67”, which means #67 DMS (Drill

Metal Standard, or wire gage number, or drill size) and is dimensionally equal to 0.0320'' or 0.813 mm diameter.

Checklist

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

Pro Rangetop models

Ù Step 1 Ù Step 2 Ù Step 3

Ù Step 4 Ù Step 5

Ù Step 6

Ù Step 7

Disassemble the rangetop (page 9).

Convert the regulator to LP gas (page 10).

Change the STAR® burner orifices according to your model and the corresponding table (page 10).

Check the rangetop for gas leaks (page 19).

Reassemble the rangetop and check STAR burner flame performance (page 20).

Set the valve screws for the STAR burners (page 22).

Place the conversion label (page 23).

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

Ù Step 10

Ù Step 11 Ù Step 12

Ù Step 13

Ù Step 14 Ù Step 15

Ù Step 16 Ù Step 17

Pro Harmony dual fuel models

Ù Step 1 Ù Step 2

Disassemble the rangetop (page 9).

Convert the regulator to LP gas (page 10).

Change the STAR burner orifices according to your model and the corresponding table (page 10).

Remove the backguard (page 15).

Change the main oven broil burner orifice to the 1.25 mm (125) orifice (page 15).

48'' models – change the aux oven broil burner orifice to the 0.75 mm (75) orifice (page 15).

Remove the oven door(s) (page 16).

Remove the kick and front panels (page 17).

Change the main oven bake burner orifice to the 1.34 mm (134) orifice (page 18).

48'' models – change the aux oven bake burner orifice to the 0.75 mm (75) orifice (page 18).

Reinstall the door(s) (page 17).

Check the rangetop and oven for gas leaks (page 19).

Reassemble the rangetop and check STAR burner flame performance (page 20).

Set the STAR burner valve screws (page 22).

Check the broil and bake burner flame performance (page 22).

Reinstall the kick and front panels (page 17).

Place the conversion label (page 23).

Disassemble the rangetop (page 9).

Convert the regulator to LP gas (page 10).

Ù Step 3

Ù Step 4 Ù Step 5

Ù Step 6

Ù Step 7

Change the STAR burner orifices according to your model and the corresponding table (page 10).

Check the rangetop for gas leaks (page 19).

Reassemble the rangetop and check STAR burner flame performance (page 20).

Set the valve screws for the STAR burners (page 22).

Place the conversion label (page 23).

Page. 7

Pro Grand gas models Pro Grand dual fuel models

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

Ù Step 10

Ù Step 11

Disassemble the rangetop (page 9).

Convert the regulator to LP gas (page 10).

Change the STAR® burner orifices according to your model and the corresponding table (page 10).

Remove the backguard (page 15).

Change the main oven broil burner orifice to the 1.25 mm (125) orifice (page 15).

48'' models – change the aux oven broil burner orifice to the 0.813 mm (813) or #67 orifice (page 15).

Remove the oven door (page 16).

Remove the kick and front panels (page 17).

Change the main oven bake burner orifice to the 1.46 mm (146) orifice (page 18).

48'' models – change the aux oven bake burner orifice to the 1.13 mm (113) orifice (page 18).

Reinstall the door(s) (page 17).

Ù Step 1 Ù Step 2 Ù Step 3

Ù Step 4 Ù Step 5

Ù Step 6

Ù Step 7

Disassemble the rangetop (page 9).

Convert the regulator to LP gas (page 10).

Change the burner orifices according to your model and the corresponding table (page 10).

Check the rangetop for gas leaks (page 19).

Reassemble the rangetop and check STAR burner flame performance (page 20).

Set the valve screws for the STAR burners (page 22).

Place the conversion label (page 23).

Ù Step 12

Ù Step 13

Ù Step 14

Ù Step 15

Ù Step 16 Ù Step 17

Check the rangetop and oven for gas leaks (page 19).

Reassemble the rangetop and check STAR burner flame performance (page 20).

Set the valve screws for the STAR burners (page 22).

Check the broil and bake burner flame performance (page 22).

Reinstall the kick and front panels (page 17).

Place the conversion label (page 23).

Page. 8

Installation procedure

Disassembling the rangetop

9 CAUTION

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.

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.

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

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

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

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

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

adjacent spill tray.

Page. 9

Converting the regulator to LP

Changing the STAR® burner

The gas regulator is located in the rangetop, left side of appliance. Exact location will vary per model.

1. Remove the conversion cap with a 7/8'' socket or wrench, or an adjustable wrench.

2. Grasp the plastic button stem firmly and pull it forcefully from the metal cap. The stem snaps snugly into an indent in the cap and may require a strong pull to remove. (Hint: it may be helpful to gently “rock” the plastic stem while pulling it from the metal cap.)

orifices

Changing “D” and “F” STAR burners only

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

NOTE: This procedure facilitates the changing of the

orifices in the “D” and “F” STAR burners only. For the smaller sized “B” burners in 305 models, this procedure will not work because the socket is too big for insertion through the orifice holders. To change “B” size STAR burners, refer to page 11.

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.

a. Spring b. Plastic button stem c. Gasket

3. Rotate the stem 180° so the letters “LP” on the stem are upside down when the cap is set flat on its head. Snap the stem back in place in this position inserting it into the indent in the metal cap.The stem should snap into place.

a. Natural gas b. LP gas

4. Reinstall conversion cap, configured for LP gas, back into top of the regulator.

To replace the STAR “D” and “F” 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.

Page. 10

2. Label each of the removed orifices, noting from which

burner they were removed, in the event the appliance is converted back to natural gas in the future.

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

Burner location Orifice size

Left front Left rear Center front Center rear Right front Right rear

To replace the “B” STAR burner orifices (or any burner size orifice)

1. From the side of the jet holder, insert a 9/32'' open end wrench into the space between the metal wire and the jet holder. Remove the gas orifice from the

STAR burner’s jet holder.

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

4. Replace orifices as indicated in the tables beginning on page 12. Ensure the orifice is completely seated and tight to the jet holder to avoid possible gas leaks.

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

burner

Changing “B” STAR burners (305 models only) and/or “D” and “F” STAR burners

This procedure can be applied when:

• Converting size “B” burners.

• Preferred by the installer to change orifices of any size burner (“B”, “D”, or “F”).

• A 7 mm or 9/32'' socket, or ¼'' nut driver is not available for use when changing the orifices on “D” and “F” burners.

a. Jet holder b. Metal wire c. Gas orifice

2. Label each of the removed orifices, noting from which burner they were removed, in the event the appliance is converted back to natural gas in the future. (See table to the left.)

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 tables beginning on page 12. Ensure the orifice is completely seated and tight to the jet holder to avoid possible gas leaks.

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

Page. 11

Pro Harmony ranges and Pro

Rangetops propane (LP)

Model 364 with griddle

burner orifice conversion kits

PALPKITHW For Pro Harmony dual fuel ranges and

Pro Rangetops with 4 and 6 burners

PALPKITHW5 For Pro Harmony dual fuel ranges and

Pro Rangetops with 5 burners

PALPKITGW For Pro Harmony gas ranges with 4 and

6 burners

PALPKITGW5 For Pro Harmony gas ranges with 5

burners

Model 304

(1) 105 (2) 115 (5) 115

(3) —

(4) 105

Model 366

(1)105 (3)105 (2)115 (4)115

Model 305

(1) 73

(3) 90

(4) 73

(2)115 (5)105

(1) 105 (3) 105 (5) 105 (2) 115 (4) 115 (6) 115

Model 364 with grill

(1) 105

(3) —

(4) 105

(2) 115 (5) 115

Page. 12

Model 486 with grill

Pro Grand propane (LP) burner orifice conversion kits

PALPKITDGW For all Pro Grand dual fuel ranges PALPKITGGW For all Pro Grand gas ranges

Model 364 with griddle

(1) 105 (3) 105 (2) 115 (4) 115 (7) 115

(5) —

(6) 105

Model 486 with griddle

(1) 105 (3) 105

(5) —

(6) 105

(2) 115 (4) 115 (7) 115

Model 486 with griddle and grill

(1) 105 (2) 126 (5) 115

(3) —

(4) 105

Model 366

(1) 105 (3) 105 (5) — (2) 115 (4) 115 (6) —

(1) 105 (3) 105 (5) 105

(2) 126 (4) 115 (6) 115

Model 364 with grill

(1) 105 (2) 126 (5) 115

(3) —

(4) 105

Page. 13

Model 364 with induction

Model 486 with griddle

(1)105 (3)105 (2)126 (4)115

Model 486 with induction

(5) —

(1) 105 (3) 105 (2)126 (4)115 (7)115

(5) —

(6) 105

Model 486 with griddle and grill

(1) 105 (3) 105 (5) 105 (2) 126 (4) 115 (6) 115

(7) —

Model 486 with grill

(1) 105 (3) 105 (2)126 (4)115 (7)115

(5) —

(6) 105

(1)105 (3)105 (5)— (2)126 (4)115 (6)—

Model 606 with grill and griddle

(1)105 (3)105 (5)— (7)105 (2)126 (4)115 (6)— (8)115

Page. 14

Model 606 with griddle

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

(1) 105 (3) 105 (2) 126 (4) 115 (7) 115

(5) —

(6) 105

Changing the broil orifice, on GAS ranges only (PRG models)

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 “Check for Gas Leaks” section of these instructions.

4. Carefully lift the backguard assembly from the range.

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.

Changing the broil burner orifice

NOTE: This procedure applies to both the main oven broil burner and, when applicable, to the auxiliary oven broil burner.

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

Page. 15

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

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

Main oven broil Aux oven broil

3. Locate the proper 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. To avoid any possible gas leak in this area, ensure the orifice is completely seated and tight to the burner orifice holding bracket and the 90° orifice elbow.

Removing and installing the oven door(s), on GAS ranges only (PRG models)

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.

Removing the oven door

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.

Description Main oven broil Aux oven broil

Pro Grand 1.25 mm (125) 0.813 mm (813) or “67” Pro Harmony 1.25 mm (125) 0.75 mm (75)

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

5. Continue to “Removing and installing the oven door(s), on GAS ranges only (PRG models)” before reattaching the backguard assembly. Once all of the broil and bake burners' orifices have been replaced and converted to LP gas, reinstall the oven doors before performing a gas leak check of all the replaced bake and broil orifices and their associated supply tube fittings.

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.

Page. 16

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.

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.

Reinstalling the oven door before leak testing the broil and bake burners

After replacing the bake burner orifices and the appliance satisfactorily gas leak tested, the oven door, kick panel, and the bottom front panel must be reinstalled.

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.

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.

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

Page. 17

Changing the bake orifice, on

a e f

GAS ranges only (PRG models)

4. Replace the orifice as indicated in the table.

Description Main oven bake

Pro Grand 1.46 mm (146)

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.

Pro Harmony 1.34 mm (134)

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. If the gas range is a single oven, perform a gas leakage check of the orifice and associated supply tube fittings per “Checking for gas leaks” on page 19. If the gas range has an auxiliary oven, proceed with the following instructions.

Changing the auxiliary oven bake burner orifice

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

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

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.

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.

b. Aux oven bake gas

line

Page. 18

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

Gas leak checking the rangetop STAR® burners

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

Main oven bake Aux oven bake

3. Replace the orifice as indicated in the table.

Description Auxiliary oven bake

Pro Grand 1.13 mm (113) Pro Harmony 0.75 mm (75)

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 “Checking for gas leaks”.

Checking for gas leaks

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.

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.

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.

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(s)

To leak check the broil burner orifice(s)

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.

Page. 19

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.

Checking the flame and burner 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.

Gas leak checking the bake orifice(s)

To leak check the oven bake burner orifice(s)

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”.

Reassemble the rangetop as follows:

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

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.

Page. 20

Checking the STAR® burner ignition and flame

Star

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

aaa

c. Light blue

d. Primary cone

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.

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

3. Test re-ignition of the XLO

and observe the carryover 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 slightly counter-clockwise until carry-over of the flame is acceptable. (See “Setting the STAR® burner valve screws” on page 22.)

• 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. Encrusted food or debris can sometimes be removed using a steel wool pad or fine wire brush.

• Burner flames that are “lazy”, with excessively-

long 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.

Yellow flames:

Further adjustment is required.

Yellow tips on outer cones:

Normal for LP gas

Soft blue flames:

Normal for natural gas

Correct burner cap Incorrect burner cap

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

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