Thermador PALPKITHC User Manual

LP GAS CONVERSION INSTRUCTIONS

For Thermador Professional® Cooktops and Dual Fuel Ranges

INSTRUCTIONS DE CONVERSION DE GAZ LP

Pour toutes les cuisinières mixtes Thermador Professional

INSTRUCCIONES DE

Model/ Modèle / Modelo: PALPKITHC

CONVERSION DE GAS LP

Para Parillas y Estufas de Todo Tipo de Gas Thermador Professional

Table of Contents

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Conversion Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 2

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Table 1: Conversion Kit Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Table 2: LP Orifice Conversion Chart (by Model Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Replacing Burner Orifices in Cooktop / Rangetop . . . . . . . . . . . . . . . . . . . . . . . . 3

Accessing the Gas Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Converting the Gas Regulator to LP Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Setting Manual Valve Screws for the Star

Check for Gas Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Burner Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Burners . . . . . . . . . . . . . . . . . . . . . . . 7

Final Step—Placement of LP Conversion Label . . . . . . . . . . . . . . . . . . . . . . . . . 11

This Thermador Appliance is made by

BSH Home Appliances Corporation

5551 McFadden Ave.

Huntington Beach, CA 92649

Questions?

1-800-735-4328

www.thermador.com

We look forward to hearing from you!

Safety

Important Safety Instructions

PLEASE READ ENTIRE INSTRUCTIONS BEFORE PROCEEDING

Natural Gas to Propane (LP) Gas Conver sion Kit for Thermador Professional

Ranges

FOR RESIDENTIAL USE ONLY

IMPORTANT:

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

INSTALLER:

Please leave these Conversion Instructions with this unit for the owner.

OWNER:

Please retain these instructions for future reference.

Cooktops and Dual Fuel

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. 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.

Contains Star Propane Gas operation for all burners in cooktop or rangetop section of the following series models.

Save the natural gas parts for possible conversion from LP back to the natural gas in the future.

This kit is used to convert Thermador Professional Cooktops and PRO-HARMONY™ Dual-Fuel Ranges from natural gas to Propane (LP) Gas operation. This kit cannot be used to convert older models of Thermador Professional cooktops or ranges (see TABLE 2

to convert Thermador Professional burners, or any other brand of appliance.

Burner orifices for proper conversion to

). This kit cannot be used

All Gas Ranges, oven

CAUTION:

Disconnect gas and electric power before making conversion. Before turning power ON, be sure that all controls are in the OFF position.

To the Service Agent:

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

• Confirm that the Propane (LP) Gas supply system is available and ready to use. This is particularly important for new construction.

• You must plan for sufficient time and resources to perform the LP 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 on Propane Gas. INCOMPLETE OR INADEQUATE GAS CONVERSION OF THE APPLIANCE CAN CREATE A SAFETY HAZARD.

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California Safe Drinking Water and Toxic Enforcement Act (Proposition 65) Notice:

WARNING:

This product contains or, through ordinary use for its intended purpose, facilitates emission of a chemical or chemicals known to the State of California to cause cancer and/or birth defects or other reproductive harm. To minimize exposure to these chemicals:

Conversion Instructions

1. Perform the LP conversion according to the instructions in this manual.

2. The conversion and adjustment to the burners should be done by a certified installer or agency to ensure proper combustion.

3. Always operate the unit according to the instructions provided with your Range or Cooktop.

4. Ensure proper ventilation with an open window or use a ventilation fan or hood when cooking with Gas.

Before You Begin

CAUTION:

Before proceeding with the conversion, shut off the gas supply to the appliance prior to disconnecting the electrical power.

Tools Needed:

• Scissors

• 7mm -or- 9/32” socket with 1/4” driver & extension

• T-30 -or- T-27 Torx driver

• 4mm hex Allen wrench

• Large, slotted screwdriver, 0.40” X .050” blade

• Extra large, slotted screwdriver, 0.60” X .060” blade

• 7/8” wrench -or- 7/8” socket & drive

• T-20 Torx driver

• Precision screwdriver, 1/8” X .020” blade

• Soap & water mixture -or- leak-check solution

Table 1: Conversion Kit Contents

Description

PALPKITHC Instructions

Foam Tape, 1” piece 418145 1 Propane Conversion

Label Plastic Bag 418148 1 Star Burner Jet

Orifice This Propane Conversion Kit contains the quantities of

parts indicated above; however , some orifices will not be used depending upon the size of the appliance being converted to LP Gas. Refer to TABLE 2 appropriate quantity of orifices to be used for each model.

Service

Number

553122 1

418146 1

617163 6

Quantity

for a list of

CAUTION:

When connecting the unit to propane gas, make certain the propane gas t ank is equippe d with its own high pressure regulator. The maximum gas pressure to this appliance is not to exceed 14.0 inches water column from the propane gas tank regulator.

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When properly converted using the prescribed LP orifices, the burners will operate at the following flow rates using Propane (LP) Gas:

Replacing Burner Orifices in Cooktop / Rangetop

•Star

Burners — 15,000 BTU/hr. [4.3 9 kW] each, using

1.15mm orifices.

WARNING:

NEVER leave the gas conversion partially completed. If the appliance is operated wh ile the gas conversion is incomplete, high levels of carbon monoxide may be emitted, or a fire or explosion may occur .

WARNING:

If the Natural Gas orifices are left in place while attempting to operate the appliance using Propane (LP) Gas, at the higher pressure setting for LP Gas, the burners will produce large flames which may emit high levels of carbon monoxide into the room, or a fire or explosion may occur .

Table 2: LP Orifice Conversion Chart (by Model Number)

NOTICE:

After the replacement of each orifice, and before reassembly of the burner, perform a brief gas leakage check of the orifice and associated fittings, per the "Check for Gas Leaks" section of these instructions.

Replace the Star® Burner orifices—all models:

• Cut a 3/8” long piece of the adhesive foam strip supplied in the kit and place over the edge of the socket driver used to replace the Star Burner or ifices, as shown. The foam piece helps to retain the orifice in the end of the socket, so it will not fall inside the appliance during orifice removal or installation.

Star Burners

Appliance Model Numbers

Pro Cooktops:

PCG304G 4 each — 1.15mm PCG366G 6 each — 1.15mm PCG364GD* 4 each — 1.15mm PCG486GD* 6 each — 1.15mm

PRO-HARMONY™ Dual-Fuel Ranges:

PRD304GH 4 each — 1.15mm PRD366GH 6 each — 1.15mm PRD364GDH* 4 each — 1.15mm PRD486GDH* 6 each — 1.15mm

NOTE:

* Model numbers with letter "D" have an Electric Griddle—which do not require conversion to gas.

High Altitude:

For safe LP conversion of an appliance for use at higher elevations, consult the local gas company for their recommendations for correct orifice sizes and any other necessary adjustments that will provide proper gas combustion at high altitudes.

Jet Orifice (# 617163)

Foam Strip

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• Use a 7mm -or- 9/32” socket with 1/4” driver & extension to reach down through the venturi and remove the Natural Gas orifice from the burner’s jet holder.

• Replace each star burner jet orifice with one of the

1.15mm, LP jets supplied in the kit. These are sized for the Star Burners to produce 15,000 BTU/hr. [4.39 kW] flow rate using Propane (LP) Gas.

Accessing the Gas Regulator

All dual-fuel range models and cooktop models have the gas regulator located inside the cooktop/rangetop, under the left side of the main top.

• The gas regulator is located inside the cooktop area, typically near the left-rear corner.

Foam Strip

• Perform a brief gas leakage test of each orifice and associated supply tube fittings, per the “Check for Gas Leaks” section of these instructions. Proper access to the burner’s jet holder can be accomplished after main top removal — see following section “Accessing the Gas Regulator” for instructions on how to remove the main top and shields.

• Each orifice is stamped “115” (1.15mm orifice diameter), as shown.

• Remove the cooking grates.

• Remove Star Burner caps, and then remove the two Torx screws from each burner base using a T-27 or T-30 driver.

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• Disconnect the female terminal on the spark wire from the male terminal on the electrode for each burner.

Important:

The locking tab on the female connector must be depressed to release from the terminal on the electrode.

• An Allen Wrench or similar item can be used as a hook to lift the main top up, sufficient for removal.

• Remove the shield under the main top, to access the components underneath.

• Using a 4mm hex wrench each of the burner pedestals.

• With the burner assemblies removed, the main top is ready to be lifted off of the appliance.

, remove the screw attaching

• The gas regulator is located near the left rear corner, inside the top area of the appliance.

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NOTE:

Fallen burner orifices left from the replacement process, can be retrieved during this step.

Converting the Gas Regulator to LP Operation

WARNING:

Harper-Wyman and Maxitrol are the two brands of gas regulators that can be used on Thermador Professional

products.

• Flip the conversion cap over to show the recessed side. “LP” will show at the bottom of the recess.

• Use an extra large, slotted screwdriver, with .60” X .060” blade, to re-install LP cap.

• Re-insert cap in top of the regulator with recess up , “LP” visible. Press down and rotate clockwise to lock cap position.

Harper-Wyman regulator conversion:

• Use a large, slotted screwdriver, with .40” X .050” blade, to remove conversion cap.

• Using a large screwdriver cap and rotate counter-clockwise to release bayo net mount.

, press down on conversion

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Maxitrol regulator conversion:

• Remove conversion cap with a 7/8” socket or wrench.

• Snap-out stem from bottom of the cap, flip stem over to show “LP” end, and snap stem back into the cap, as shown.

Flip Stem

Setting Manual Valve Screws for the Star® Burners

Screw driver for valve screw setting:

A precision screwdriver with high-strength blade, similar to the *Wiha no. 26033 [0.50mm] thickness tip, shown below, should be used to reposition the bypass screws for minimum flow settings on manual valves.

*Used by permission from Wiha Quality Tools division of Willi

Hahn Corporation USA.

, with 1/8" [3.0mm] wide, .020"

• Re-install conversion cap —configured for LP gas— back into top of the Maxitrol regulator.

Valve Screw

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Setting valve screws on PRO-HARMONY™ Dual-Fuel Ranges

-and- Pro Cooktops:

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

• To engage the valve screw, insert the precision screwdriver with 1/8” blade into the hole in the bezel created by removal of the mounting screw.

• Turn the valve screw clockwise just until "bottom out" position is reached. DO NOT over-tighten the valve screw.

NOTE:

• It is necessary that the two valves for XLO operation (farthest left on control panel) are in the OFF position for proper access to the valve screws through clearance holes in the XLO potentiometers.

• Remove the bezel-mounting screw located to the right of the valve stem, using a T-20 Torx driver

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Check for Gas Leaks

WARNING:

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

Burner Testing and Adjustment

Checking manifold pressure

(if necessary): Gas leakage checking using a liquid solution:

The replacement orifices in the PALPKITHC, LP conversion kit, have straight threads (not pipe threads) and do not require thread sealing compound.

Leak-checking should occur after the orifice conversio n is complete, and before the burner is reassembled and tested.

• Make sure that all of the LP orifices have been

tightened and that all valves and controls are in the OFF position.

• Turn on electrical and gas supplies.

• Briefly evaluate the threaded connection of each

replaced orifice individually—that is, one orifice at a time.

• Spray a g enero us a mou nt of so ap & water m i xture—or

other solution designed for checking gas leaks—on the threaded junction at the base of the orifice. Avoid spraying electrical devices. (A 25% dishwashing liquid to water mixture is effective for this.)

• Briefly turn on the valve or control while blocking the

orifice hole with a soft pencil eraser, your finger, or something similar.

Note:

It is normal to hear spark ignition noise during this process.

• Monitor the base of the orifice junction to see if bubbles

are forming anywhere around the threaded connection.

• Bubbles forming are indications of gas leaks. The

amount and sizes of the bubbles are indications of the severity of the leakage.

• Repair all gas leaks immediately after their discovery;

this can often be accomplished by re-tightening the orifice.

• Since considerable torque is sometimes used during

orifice replacement, leak-check other fitting junctions leading up to the orifice as well.

• Turn off the gas and electrical supplies.

• Reassemble the appliance in preparation for testing

the newly-converted burner systems.

Checking the appliance manifold pressure is NOT

REQUIRED for the Propane Gas conversion; however, if

the outlet pressure of the gas regulator or the inlet pressure

to the appliance is suspect, the following procedure can be

used to check the manifold pressure.

• A manifold pressure measurement can be acquired at one of the star burner orifices, as shown.

• Attach a portable or hand-held manometer, that reads pressure in inches water column (“WC), using a piece of PVC or vinyl tubing.

• Turn on the electrical and gas supplies to the cooktop or range.

• Turn on one of the top burners to HI position. This is important to acquire a true pressure reading u nder g as flow conditions.

• Turn the manual valve for the burner being monitored to HI position. (Spark ignition noise will be heard coming from this burner.)

• The manifold pressure reading on the manometer should be between 9.50 and 10.50“WC for an appliance regulator converted to LP gas.

• If the manifold pressure reading is below this range, verify that the regulator has been properly converted for use with LP gas, and that the inlet pressure to the appliance is between 11.0 and 14.0”WC.

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Checking LP flame characteristics & burner performance:

To observe the burner flames, remove th e minimum number of components necessary for an un-obstructed view. It may be ne ce ssary to tu rn off lights or close window blinds to darken the room for easier viewing of the flame.

• Test Burner Ignition. Push in the burner control knob and turn counter-clockwise (CCW) to “HI”. The ignitor electrode & spark module will produce a clicking sound. Once the air has been purged from the supply lines, the burner should light within four (4) seconds.

• The LP flames should be stable, with no excessive noise. The inner cones of the individual flames should be well defined and distinctly separate from each other .

• Adjust the burner’s control valve to “LO” or “SIM” 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, and then observe the burner’s ability to re-ignite and wrap around (“carry-over”) the burner within several seconds. The flame “carry-over” is essential for proper burner ignition and re-ignition.

• Test re-ignition of the two Star of the appliance by turning the control knobs to “XLO” and observe the carry-over of the small simmer flames as the XLO system cycles the two burners on and off.

• If the flame performance is not acceptable, verify that the burner has the correct size LP orifice installed, and that the regulator has been properly converted for LP Gas.

• If the burner flame is uneven, flutters, makes ex cessive noise, or lifts, some of the slots in the burne r 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-to-remove, encrusted food or debris can sometimes be removed using a steel wool pad or fine-wire brush.

• A flame that is “lazy”, with excessively-long flames, can be created by an in-correctly fitted burner cap. Many of the outer mantles of the individual flames will tend to “coalesce” or blend together. Verify that the b urner cap is seated properly on its burner base. The cap should fit reasonably flat when correctly-positioned in the ba se and not rock significantly. (See illustration below.)

Burners on the left side

Dark Blue

Secondary Cone

Light Blue

Primary Cone

• Portions of the flame, along the burner, should not exhibit excessive or continuous indications of “lifting” or “lazy flame”.

• 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.

Correct Burner Cap Placement

Incorrect Burner

Cap Placement

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