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:
PLPKIT
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
Possible Tools Needed for All Orifice
Conversions . . . . . . . . . . . . . . . . . . . . 2
Table 1: Conversion Kit Contents . . . . 2
Table 2: LP Orifice Conversion Chart—
by Model Number (older models /
newer models) . . . . . . . . . . . . . . . . . . 3
Replacing Burner Orifices in Cooktop /
Rangetop . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replace the Star® Burner orifices—
all models . . . . . . . . . . . . . . . . . . . . . . 5
Replace the Gas Grill Orifice—if equipped
with Open-Grate Style Grill . . . . . . . . . 6
Replace the Gas Grill Orifice—if equipped
with Solid-Plate Style Grill . . . . . . . . . . 7
Replace the Gas Griddle Orifice—
if so equipped . . . . . . . . . . . . . . . . . . . 9
Replace the Wok Orifice in Pro Cooktop—
if so equipped . . . . . . . . . . . . . . . . . . 10
Accessing the Gas Regulator . . . . . . . 11
Converting the Regulator to
LP Operation . . . . . . . . . . . . . . . . . . . . . 12
Harper-Wyman regulator conversion 12
Maxitrol regulator conversion . . . . . . 13
Setting Manual Valve Screws for
Cooktop / Rangetop . . . . . . . . . . . . . . . 13
Screw driver for valve screw setting . 13
PRO-GRAND™ and PRO-HARMONY™
Dual-Fuel Ranges and Pro Cooktops 14
Older models of Professional® Dual-Fuel
Ranges and Cooktops . . . . . . . . . . . . 14
Check for Gas Leaks . . . . . . . . . . . . . . 15
Gas leakage checking using a liquid
solution . . . . . . . . . . . . . . . . . . . . . . . 15
Burner Testing and Adjustment . . . . . 16
Checking manifold pressure
(if necessary) . . . . . . . . . . . . . . . . . . . 16
Checking LP flame characteristics and
burner performance . . . . . . . . . . . . . . 16
Tubular and wok burner performance
and final air-shutter adjustments
(if necessary) . . . . . . . . . . . . . . . . . . . 17
Final Step—Placement of LP Conversion
Label . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Location of Rating Labels on Thermador
Professional® products . . . . . . . . . . . 19
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 Conversion 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.
®
Contains Star
conversion to 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, PRO-GRAND™ Dual-Fuel Ranges, and PROHARMONY™ 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 other than those identified in these instructions
(see TABLE 2). This kit cannot be used to convert
Thermador Professional
or any other brand of appliance.
Burner orifices and hood orifices for proper
®
Cooktops and Dual Fuel
®
®
All Gas Ranges, oven burners,
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.
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 part icu lar ly
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.
English 1
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 mi n im iz e
exposure to these chemicals:
Conversion Instructions
Before You Begin
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.
CAUTION:
Before proceeding with the conversion, shut off
the gas supply to the appliance prior to
disconnecting the electrical power.
Possible Tools Needed for All Orifice Conversions
• Scissors
• 7mm nut driver
• 1/2" deep-well socket and drive
• 1/4" nut driver or wrench
• Large, slotted screwdriver, .40" X .050" blade
• Extra large, slotted screwdriver, .60" X .060" blade
• 7/8" wrench or socket and drive
• Precision, slotted screwdriver, 1/8" X .020" blade
• Phillips #2 screwdriver
• Soap and water mixture or leak-check solution
Table 1: Conversion Kit Contents
Description
PLPKIT Instructions 552805 1 Foam Tape, 1” piece 418145 1 Propane Conversion
Label
Service
Number
418146 1
Quantity
Table 1: Conversion Kit Contents
Description
Plastic Bag 418148 1 Star Burner Jet
Orifice
Grill Hood Orifice
(open grate style)
Grill Hood Orifice
(solid plate style) Griddle Hood Orifice 418150 1 Wok Hood Orifice 414918 1 This Propane Conversion Kit contains the quantities of
parts indicated above; however, some parts will not be
used depending upon the type and model of appliance
being converted to LP Gas. Refer to Table 2 for a listing
of appropriate combination of orifices to be used for
each particular model.
Service
Number
424851 6
418151 1
414916 1
Quantity
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 from the propane gas tank
regulator.
English 2
When properly converted using the prescribed LP orifices,
the burners will operate at the following flow rates using
Propane (LP) Gas:
•Star
• Gas Grill (open grate style) — 17,000 BTU/hr. [4.98
• Gas Grill (solid plate style) — 12,000 BTU/hr. [3.51
• Gas Griddle — 13,000 BTU/hr. [3.81 kW], using a #57
• Gas Wok — 24,500 BTU/hr. [7.17 kW], using a #54 or
Table 2: LP Orifice Conversion Chart—by Model Number (older models / newer models)
®
Burners — 13,000 BTU/hr . [3.81 kW] each, u sing
1.07mm orifices.
kW], using a 1.20mm orifice.
kW], using a #59 orifice.
or 1.10mm orifice.
1.40mm orifice.
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.
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.
Appliance Model Numbers
(older/newer)
Pro Cooktops:
PC304 / PCG304E 4 each - 1.07mm
PC366 / PCG366E 6 each - 1.07mm
PC364GD / (no newer model) 4 each - 1.07mm #57 or 1.10mm
PC364GE / PCG364ED 4 each - 1.07mm
PC364GL / PCG364EL 4 each - 1.07mm 1.20mm (grate) or
PC486GD / (no newer model) 6 each - 1.07mm #57 or 1.10mm
PC486GE / PCG486ED 6 each - 1.07mm
PC486GL / PCG486EL 6 each - 1.07mm 1.20mm (grate) or
PC484GG / (no newer model) 4 each - 1.07mm 1.20mm (open grate
PC484GGE / PCG484EC 4 each - 1.07mm 1.20mm (grate) or
PC484WK / PCG484EW 4 each - 1.07mm #54 or 1.40mm
PC484GE / PCD484EE 4 each - 1.07mm
Star Burners
#424851
Jet Orifice
Gas Grill*
(Grate/Plate Styles)
#418151 or #414916
Hood Orifice
#59 (plate)
#59 (plate)
grill only)
#59 (plate)
Gas Griddle**
#418150
Hood Orifice
#57 or 1.10mm
Gas Wok
#414918
Hood Orifice
PRO-GRAND™ Dual-Fuel Ranges (27" depth):
PD304 / PRD304EG 4 each - 1.07mm
PD366 / PRD366EG and
PRD366EPG
PD364GD / (no newer model) 4 each - 1.07mm #57 or 1.10mm
PD364GE / PRD364EDG and
PRD364EDPG
6 each - 1.07mm
4 each - 1.07mm
English 3
Table 2: LP Orifice Conversion Chart—by Model Number (older models / newer models)
Appliance Model Numbers
(older/newer)
PD364GL / PRD364ELG 4 each - 1.07mm 1.20mm (grate) or
PD486GD / (no newer model) 6 each - 1.07mm #57 or 1.10mm
PD486GE / PRD486EDG and
PRD486EDPG
PD486GL / PRD486ELG 6 each - 1.07mm 1.20mm (grate) or
PD484GG / (no newer model) 4 each - 1.07mm 1.20mm (open grate
PD484GGE / PRD484ECG 4 each - 1.07mm 1.20mm (grate) or
PD484GE / PRD484EEG 4 each - 1.07mm
PRO-HARMONY™ Dual-Fuel Ranges (24" depth):
DP304 / PRD304EH 4 each - 1.07mm
DP366 / PRD366EH 6 each - 1.07mm
DP364GE / PRD364EDH 4 each - 1.07mm
DP364GL / PRD364ELH 4 each - 1.07mm #59 (solid plate grill
Star Burners
#424851
Jet Orifice
6 each - 1.07mm
Gas Grill*
(Grate/Plate Styles)
#418151 or #414916
Hood Orifice
#59 (plate)
#59 (plate)
grill only)
#59 (plate)
only)
Gas Griddle**
#418150
Hood Orifice
#57 or 1.10mm
Gas Wok
#414918
Hood Orifice
(no older model) / PRD486EDH 6 each - 1.07mm
(no older model) / PRD486ELH 6 each - 1.07mm #59 (solid plate grill
only)
(no older model) / PRD484ECH 4 each - 1.07mm #59 (solid plate grill
only)
(no older model) / PRD484EEH 4 each - 1.07mm
NOTES:
* Some newer-model Pro Cooktops and Pro-Grand DF Ranges have the open grate style Gas Grill.
** Older model numbers with letters "GE" and newer "E" model numbers that have letters "ED", "EC", or "EE" are for
models with Electric Griddle -- which do not require conversion.
Examples
High Altitude:
Many of the Thermador appliances that are serviced by this
Propane (LP) conversion kit are CSA-certified for safe
operation on LP Gas up to an elevation of 10,200 ft.
[3,109m] above sea level without additional alterations. For
: "PC484GGE", "DP364GE", "PRD364EDG", "PRD484ECH", or "PCD484EE".
safe LP conversion of an appliance for use at higher
elevations, consult the local gas company for their
recommendations for correct orifice sizes an d an y oth er
necessary adjustments that will provide proper gas
combustion at high altitudes.
English 4
Replacing Burner Orifices in Cooktop / Rangetop
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 nut
®
driver used to replace the Star
shown.
Burner orifices, as
• Use a 7mm nut driver to reach down through the
venturi and remove the orifice from the burner's jet
holder.
• Replace each star burner jet orifice with one of the
1.07mm, LP jets supplied in the kit. These are sized for
the Star
flow rate using Propane (LP) Gas.
®
Burners to produce 13,000 BTU/hr . [3.81 kW]
Foam Strip
The foam piece 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.
• 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 spill
tray removal—see "Accessing the Gas Regulator"
section for instructions on how to remove the spill tray.
English 5
• Each orifice is stamped "107" (for 1.07mm orifice
diameter) as shown.
Replace the Gas Grill Orifice—if equipped with Open-Grate Style Grill
This style grill is an open-top design that can be identified
by its "U" shaped burner tube and corrugated stainlesssteel radiant, as shown in the exploded view.
WARNING
The grill must be assembled as shown. The drip
tray heat shields must be in place, and the
burner must be properly positioned relative to
the gas supply. Incorrect assembly of the grill
may result in unsafe or hazardous conditions
during operation.
• Remove the Grill Grate, Radiant, and Grill Burner from
the Grill Can Assembly.
• Pull back the metal lever at the front of the Grill Burner
to release it, and then remove the Grill Burner.
• Use a 1/2" deep-well socket to remove the Grill hood
orifice and replace with the 1.20mm LP hoo d orifice
supplied in this kit.
• Pre-adjust the burner's air shutter to approximately
75% closed (approximately 0.20" opening) position and
re-tighten screw(s) using a 1/4" nut driver or wrench.
• Re-insert the venturi end of the Grill Burner into the two
slots at the back of the Grill Can Assembly. Then rotate
the other end of the burner into position and lock the
tab on the front of the burner into the slot in the Heat
Deflector.
• Re-install the stainless steel Radiant onto the two studs
on each end of the Grill Can Assembly.
English 6
• Replace the Grill Grate such that the raised food
containment rail is oriented toward the back of the Grill.
• The "1.20MM"-stamped hood orifice is sized to
produce 17,000 BTU/hr . [4.98 kW], using Propane (L P)
Gas.
Replace the Gas Grill Orifice—if equipped with Solid-Plate Style Grill
This style grill design can be identified by its ribbed grill
plate and its "T" shaped burner, as shown in the exploded
view.
• After the orifice conversion, gas leak check, and reinstallation of the grill burner, check that the electrode
and bracket spacing to the burner is within the distance
range shown here.
• Verify that the grill burner's air shutter is properly readjusted, per the “Burner Testing and Adjustment"
section of these instructions, as air-shutter position can
also influence ignition performance.
• Remove the Grill Plate. Some Grills have a Grill Plate
and Frame as two separate pieces, similar to the Gas
Griddle on the next pages.
English 7
• Remove the screws at each end of the Flame
Spreader, tilt to ward you, and pull the spreader out of
the front slot in the Grill Box.
• Use a 1/2" deep-well socket to remove the Grill hood
orifice.
• The LP orifice is a #59 drill (stamped "59"), which is
sized to produce 12,000 BTU/hr. [3.51 kW], using
Propane Gas.
• Pre-adjust the burner's air shutter to approximately
75% closed (approximately 0.20" opening) position and
re-tighten screw(s) using a 1/4" nut driver or wrench.
• After the orifice conversion, gas leak check, and resetting of the grill burner, check that the Hot-Surface
Ignitor (HSI) spacing to the burner is within the
distance ranges shown, for the following two types of
ignitors used with Grill models.
English 8
Replace the Gas Griddle Orifice— if so equipped
• The LP orifice is a #57 drill (stamped "57"), which is
sized to produce 13,000 BTU/hr. [3.81 kW], using
Propane (LP) Gas. The orifice diameter could also be
1.10mm; in which case, the hood orifice could have a
"110" or "1.10MM" stamp.
• Pre-adjust the burner's air shutter to approximately
75% closed (approximately 0.20" opening) position and
re-tighten screw(s) using a 1/4" nut driver or wrench.
• Remove the Griddle's Grease Tray, Griddle Plate and
Griddle Frame. These items are not held with
fasteners, so they should lift up and out easily.
• Remove the screws on each end of the Flame
Spreader, while paying attention not to drop the
spacers inside the cooktop / rangetop area.
• Remove the Cover Plate with four (4) screws, which
covers the Griddle Burner's venturi at the bottom of the
Griddle Box.
• Lift out the Griddle Burner.
• Use a 1/2" deep-well socket to remove the Grill hood
orifice. When installing the LP orifice, take extra care
not to bend the sheet metal orifice bracket.
• After the orifice conversion, gas leak check, and reinstallation of the griddle burner, check that the ignitor
electrode tip spacing to the surface of the burner
(tangent point) is approximately 0.105". There is some
movement available in the burner mounting, on each
end, to adjust this spacing if needed.
English 9
Replace the Wok Orifice in Pro Cooktop— if so equipped
• Remove the two screws that attach the pilot burner to
the bracket on the Wok Top Support Assembly.
• Lift the Top Assembly straight up, away from the Wok
Chassis a few inches, and then remove the Wok
Burner.
• Lift out the Wok Top Support Assembly. This will
expose the Safety Valve.
Wok Safety Valve with Hood Orifice
• The LP orifice for the Wok is a #54 drill (stamped "54"),
which is sized to produce 24,500 BTU/hr. [7.17 kW],
when using Propane (LP) Gas. The orifice diameter
could also be 1.40mm; in which case, the hood orifice
could have a "140" or "1.40MM" stamp.
• Use a 1/2" deep-well socket to remove the hood orifice
from the safety valve.
NOTE:
The pilot burner does not require orifice conversion for
operation on Propane Gas.
• Pre-adjust the air shutter on the Wok Burner to fully
open position.
• Replace the Wok Top Assembly.
• Re-install the wok burner. Make sure that the burner's
venturi is properly positioned on the hood orifice, and
that the bottom of the burner head is positioned
between the pins on the cross member at the base of
the top support.
• Re-attach the pilot burner to the bracket on the Wok
Top Support.
English 10
Accessing the Gas Regulator
All dual-fuel range models and some cooktop models have
the gas regulator located inside the cooktop/rangetop,
under the left spill tray .
• Gas regulator is located inside cooktop, left side
• Remove the cooking grates
• Remove Star
both burners using a 13/16" socket or wrench.
• Disconnect the spark wire from the tab on the spark
electrode for each burner.
®
Burner caps, then remove venturi from
• Remove aluminum trim from sides of left spill tray
• Remove the shield on some models. Some models
have a double-width shield that extends under ad jacent
spill tray.
English 11
• The gas regulator is located near the left rear corner
inside the cooktop area of appliance.
NOTE:
Fallen star-burner orifices inside cooktop area, from the
replacement process, can usually be retrieved during this
step.
Converting the Regulator to LP Operation
WARNING:
If the Natural Gas orifices are left in place while attempting to operate the appliance using Prop ane (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. All orifice replacements for LP operation
should be performed prior to regulator conversion.
Harper-Wyman and Maxitrol are the two brands of gas regulators that are used on Thermador Professional
Harper-Wyman regulator conversion
• Use a large, slotted screwdriver, with .40" X .050"
blade, to remove conversion cap.
• Using a large screwdriver, press down on conversion
cap and rotate counter-clockwise to release bayonet
mount.
• 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 rece ss up ,
"LP" visible. Press down and rotate clockwise to lock
cap position.
®
products.
English 12
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
• Re-install conversion cap -configured for LP gas- back
into top of the Maxitrol regulator.
Setting Manual Valve Screws for Cooktop / Rangetop
Screw driver for valve screw setting
A precision screwdriver with high-strength blade, similar to
the *Wiha no. 26033, with 1/8" [3.0mm] wide, .020"
[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.
English 13
PRO-GRAND™ and PRO-HARMONY™ Dual-Fuel Ranges and Pro Cooktops
• Remove knob from the valve stem by slowly pulling
knob straight out, away from control panel.
• For newer models, remove the bezel-mounting screw
located to the right of the valve stem.
• Turn the valve screw clockwise just until "bottom out"
position is reached. DO NOT over-tighten the valve
screw.
• For open-grate style Grill or Wok valves — After turning
valve screw to bottom position, turn screw counterclockwise one-half (1/2) turn.
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.
• Solid-plate style Gas Grill and Gas Griddle are
controlled by thermostats and do not have valves that
require adjustments.
Older models of Professional® Dual-Fuel Ranges and Cooktops
• Remove knob from the valve stem by slowly pulling
knob straight out, away from control panel.
• To engage the valve screw, insert precision
screwdriver into hole in bezel created by removal of
mounting screw.
English 14
• Valve screws on older models can be accessed directly
through the control panel, without removing bezel
screws.
Check for Gas Leaks
WARNING:
DO NOT use a flame of any kind to check for gas leaks.
WARNING:
Hot Surface Ignitor (HSI) for Grill gets very hot and can cause severe burns.
Gas leakage checking using a liquid solution
All of the replacement orifices in the PLPKIT, LP conversion
kit, have straight threads (not pipe threads) and do not
require thread sealing compound.
Leak-checking should occur after the orifice conversion 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 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. 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. It is normal to hear spark ignition
noise during this process. —Avoid extreme heat from
the Grill HSI on models so equipped. See warning
above.—
• Monitor the base of the orifice junction to see if bubbles
are forming anywhere around the threaded co nnection.
• 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.
English 15
Burner Testing and Adjustment
Checking manifold pressure (if necessary)
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.
Checking LP flame characteristics and burner performance
To observe the burner flames, loosen or remove the
minimum number of components necessary for an unobstructed view. It may be necessary to turn 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 and 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.
• 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 under 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.
• 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 .
• 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
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(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.
• Adjust the burner's control valve or thermostat 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.
• For un-acceptable performance of a Star
verify that the burner cap is seated properly in its
burner base. The cap should fit reasonably flat when
correctly-positioned in the base and not rock
significantly.
• If the burner flame is uneven, flutters, makes excessive
noise, or lifts, some of the ports in the burner cap may
be blocked with food spillage or other debris. Clogged
ports can be cleared using a straightened paper clip,
needle, or similar object. This is also applicable for
blocked ports in Grill or Griddle Burners.
• Additionally , hardened food spillage or other debris can
block some of the small carry-over channels in the
®
Star
Burner base, which can inhibit the flame from
wrapping around the burner. The channels can be
cleared using a wire brush.
®
Burners on the left side
®
Burner,
Tubular and wok burner performance and final air-shutter adjustments (if necessary)
Propane (LP) Gas is heavier, with greater density than
Natural Gas, and is distributed within the appliance at
higher pressure. The differences in properties an d
application cause LP Gas to entrain different amounts of
primary air which usually requires different air-sh utter
openings, as compared to Natural Gas applications for the
same or similar BTU ratings.
Burner for "solid plate" style Grill or Griddle
• A "too open" air shutter position creates noticeable
"lifting" (also called "blowing") of the flame - which can
degrade carry-over performance of the burner. This
condition can also create excessive noise.
• A flame that is "lazy", with excessively-long flames that
are reaching for air, is created by a "too closed" air
shutter. Many of the outer mantle s of the individual
flames tend to "coalesce" or blend together. Excessive
yellow color in the flame can also occur with an
excessively-closed shutter.
If air-shutter adjustment is needed, remove the burner from
the appliance. Loosen the shutter's retaining screw using a
1/4-inch nut driver or wrench and rotate the shutter to its
new position. If less than 50% opening is desired, move the
retaining screw to the alternate location shown on the next
page and rotate the shutter to its new position. Re-install
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the burner and re-evaluate flame performance
characteristics. Repeat this process as necessary to
produce acceptable flame performance.
• For less than 50% air-shutter opening, move the
retaining screw to the alternate location and rotate the
air shutter in the clockwise (CW) direction as needed.
Final Step—Placement of LP Conversion Label
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.
IMPORTANT:
For proper identification and evidence of the appliance's
conversion to Propane (LP) Gas, affix the provided
Conversion Label in a location next to the Rating Labels on
the appliance. This is particularly important if the converted
appliance is re-installed in a different home.
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