Thermador PRD486NLGU User Manual
LP GAS CONVERSION
INSTRUCTIONS
For THERMADOR PROFESSIONAL® Pro Grand
Dual Fuel Ranges
INSTRUCTIONS DE CONVERSION
AU GPL
Pour les cuisinières mixtes au gaz PROFESSIONALmc
Pro Grand de THERMADOR
INSTRUCCIONES DE
Models/
Modèles/
Modelos:
PRD364JDGC
PRD364JDGU
PRD366JGC
PRD366JGU
PRD486JDGC
PRD486JDGU
PRD48JDSGC
PRD48JDSGU
PRD364NLGC
PRD364NLGU
PRD484NCGC
PRD484NCGU
PRD486NLGC
PRD486NLGU
PRD48NCSGC
PRD48NCSGU
PRD48NLSGC
PRD48NLSGU
CONVERSION AL GLP
Para las estufas mixtas PROFESSIONAL® Pro Grand
Table of Contents
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Important Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Conversion Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Conversion Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembling the Cooktop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Regulator Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacing the Burner Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reassemble the Cooktop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Setting Valve Screws for the Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Check for Gas Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Checking manifold pressure (if necessary) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Check Flame Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Conversion Label Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Customer Support, Accessories & 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!
Safety
IMPORTANT SAFETY INSTRUCTIONS
READ AND SAVE THESE INSTRUCTIONS
This kit is used to convert THERMADOR
PROFESSIONAL
natural gas to propane (LP) gas operation. This kit cannot
be used to convert older models of THERMADOR
PROFESSIONAL rangetops or ranges other than those
identified in these instructions (see applicable models on
the front cover). This kit cannot be used to convert all-gas
ranges, oven burners, or any other brand of appliance.
IMPORTANT: Only a qualified service technician or
installer should make this conversion.
INSTALLER: Please leave these conversion instructions
with this unit for the owner.
®
PRO GRAND® dual fuel ranges, from
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.
OWNER: Please retain these instructions for future
reference.
CAUTION
Disconnect gas and electric power before making
conversion. Before turning power ON, be sure that all
controls are in the OFF position.
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.
WARNING
State of California Proposition 65 Warnings:
This product contains chemicals known to the State of
California to cause cancer, birth defects or other
reproductive harm.
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.
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.
Save the natural gas parts for possible conversion from LP
back to the natural gas in the future.
English 1
Conversion Instructions
Before You Begin Conversion Preparation
1. Shut off the gas supply to the appliance prior to
CAUTION!
BEFORE PROCEEDING WITH THE CONVERSION,
SHUT OFF THE GAS SUPPLY TO THE APPLIANCE
PRIOR TO DISCONNECTING THE ELECTRICAL
POWER.
TOOLS NEEDED
Scissors
T-30 Torx screwdriver
T-20 Torx screwdriver
1/4" nut driver
7/8" socket or adjustable wrench
Flat-head screwdriver, 1/8" X .020" blade (included)
ITEMS INCLUDED
disconnecting the electrical power.
2. Cut a 3/8" long piece of the adhesive foam tape. Place
foam tape over the edge of the nut driver used to
replace the burner orifices, as shown.
• 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.
DESCRIPTION QUANTITY
Instructions 1
Foam Tape, 1" piece 1
Propane Conversion Label 1
®
STAR
STAR
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.
Burner Jet Orifice (1.15 mm) 5
®
Burner Jet Orifice (1.25 mm) 1
CAUTION
Disassembling the Cooktop
IMPORTANT: Ensure that the power is turned OFF at
the breaker and the gas supply is turned OFF.
1. Remove the cooktop grates.
2. Remove the burner caps.
3. From each burner base, remove the two burner base
screws with a T-30 Torx screwdriver.
English 2
4. To facilitate the removal of the spill trays, depending on
Burner Pedestal
model, remove the (3) or (4) T-20 Torx stainless screws
in the front face of the included Flush Island Trim.
5. Disconnect the igniter.
A.) Disconnecting a Two Piece Igniter
1) Carefully pull up on the burner base.
Burner Base
Electrode
6. From each burner pedestal, remove the burner
pedestal screws with a T-30 Torx screwdriver.
Burner Pedestal
Burner Pedestal
Venturi
7. Carefully remove the burner pedestal and the venturi.
8. Remove the spill trays by rotating the trays up and out
the back.
Ignitor Housing
Ignitor Wire
B.) Disconnecting a Single Piece Igniter
1) Carefully pull up on the burner base.
2) 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.
Burner Base
Electrode
Ignitor Wire
9. Remove the heat shield, on some models. Some
models have a double-width shield that extends under
adjacent spill tray.
Regulator Conversion
The gas regulator is located in the cooktop, left side of
appliance. Exact location will vary per model.
English 3
1. Remove conversion cap with a 7/8" socket or wrench.
1.15
1.15
1.15
1.15
1.15
1.25
2. Read the letters on the stem. You will see “NAT” at the
bottom of the stem. Snap-out the plunger from bottom
of the conversion cap.
3. Flip the stem over to the "LP" end, and snap the
plunger back into the cap, as shown.
Replace the Burner Orifices
1. Use a 7 mm or a 9/32” socket with 1/4” nut driver to
reach down through the jet holders and remove the
Natural Gas orifice from the burner’s jet holder.
2. Five orifices are stamped “1.15” (1.15 mm orifice
diameter) and one orifice is stamped “1.25” (1.25 mm
orifice diameter).
LP
NAT
4. Re-install conversion cap, configured for LP gas, back
into top of the regulator.
Brass Cap
Sealing Washer
Plunger
1.15 x 5 1.25 x 1
Replace the right-front burner orifice (XHI) with the
1.25 mm LP burner orifice. Replace the remaining
®
STAR
jet orifices.
• All of the replacement orifices in the conversion kit
IMPORTANT: DO NOT install the 1.25 mm LP orifice at
any other burner location than the right-front position.
1.15
1.15 1.15
burner jet orifices with one of the 1.15 mm LP
have straight threads (not pipe threads) and do not
require thread sealing compound.
1.15
1.15
1.15
English 4
Regulator Body
1.15 1.15
1.15
3. Perform a gas leakage test of each orifice and
associated supply tube fittings. See “Check for Gas
Leaks” on page 6.
• Leak-checking should occur after the orifice
conversion is complete, and before the burner is
reassembled and tested.
1.15
1.25
1.25
Reassemble the Cooktop
1. For the single piece ignitor, carefully feed the wires
through the heat shields, if applicable. Ensure that the
ignitor wires do not crimp.
For the two piece ignitor, reinstall the heat shield, if
applicable (wire feed not necessary).
2. For the single piece ignitor, carefully feed the wires
through the spill trays. Ensure that the ignitor wires do
not crimp.
For the two piece ignitor, reinstall the spill trays (wire
feed not necessary).
3. Reinstall the Flush Island Trim with T-20 Torx screws.
4. For the single piece ignitor, carefully feed the ignitor
wires through the burner pedestals.
For the two piece ignitor, reinstall the burner pedestals
(wire feed not necessary).
5. Insert the venturi into the burner pedestals. Secure with
the black T-30 Torx screws, starting both before fully
securing either screw. Ensure that the venturi does not
‘lock down’. The venturi should be pulled out smoothly
and easily once the pedestals have been secured.
6. For the single piece ignitor, reconnect the ignitor wire to
the electrode on the burner base. Carefully feed the
ignitor wires back through their burner pedestals while
setting the burner bases back into place. Ensure that
the wires do not crimp or bunch.
For the two piece ignitor, set the burner bases back on
the burner pedestals (wire feed not necessary).
7. Secure with the burner bases with T-30 Torx screws,
starting both before fully securing either screw.
8. Replace burner caps and grates.
Setting valve screws
Valve Screw
1. Shut off the gas supply to the appliance.
2. Disconnect the electrical power.
3. Remove knob from the valve stem by slowly pulling
knob straight out, away from the control panel.
4. Remove the bezel-mounting screw located to the right
of the valve stem, using a
T-20 Torx driver.
Setting Valve Screws for the
Burners
Screw driver for valve screw setting
A flat-head screwdriver with an 1/8" [3.0 mm] wide, .020"
[0.50 mm] thickness tip (included) is used to reposition the
valve screws for minimum flow settings on manual valves.
Remove the protective cap before use.
5. To engage the valve screw, insert the included
blade screwdriver with 1/8” blade into the hole in the
bezel created by removal of the mounting screw. You
should feel the engagement of the screwdriver and the
valve screw.
flat-
English 5
6. FOR STANDARD BURNERS, adjust the valve screw
By-pass screw access
hole with valve in OFF
position.
By-pass screw access
hole with valve in LOW
position.
by turning the valve screw clockwise about an
1/8 turn. 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.
7. FOR EXTRALOW BURNERS, auto-cycling of the
®
burners allows for exceptional simmer results
XLO
and adjustment is not required. However, adjustment
to the valve screw may be performed to suit individual
preference. Always turn OFF the power to the
appliance before adjusting flame settings. Turn the
valve stem to the LOW position for proper access to
the valve screws through clearance holes in the
potentiometers.
By-pass screw access
By-pass screw access
hole with valve in OFF
hole with valve in OFF
position.
position.
By-pass screw access
By-pass screw access
hole with valve in LOW
hole with valve in LOW
position.
position.
5. 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.
6. Repair all gas leaks immediately after their discovery;
this can often be accomplished by re-tightening the
orifice.
7. Since considerable torque is sometimes used during
orifice replacement, leak-check other fitting junctions
leading up to the orifice as well.
8. Turn off the gas and electrical supplies.
9. Reassemble the appliance in preparation for testing
the newly-converted burner systems.
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.
Check for Gas Leaks
WARNING!
DO NOT use a flame of any kind to check for gas leaks.
Gas leakage checking using a liquid
solution
Leak-checking should occur after the orifice conversion is
complete, and before the burner is reassembled and
tested.
1. Make sure that all of the LP orifices have been
tightened and that all valves and controls are in the
OFF position.
2. Turn on electrical 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. Avoid
spraying electrical devices. (A 25% dishwashing liquid
to water mixture is effective for this.)
4. 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.
1. Attach a portable or hand-held manometer, that reads
pressure in inches water column (WC), using a piece of
PVC or vinyl tubing.
2. Turn on the electrical and gas supplies to the
appliance.
3. Turn one of the cooktop burners to HI position. This is
important to acquire a true pressure reading under gas
flow conditions.
4. Turn the manual valve for the burner being monitored
to HI position. (Spark ignition noise will be heard
coming from this burner.)
English 6
• The manifold pressure reading on the manometer
Star
®
Star
®
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.
Check Flame Characteristics
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.
1. Test STAR
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
NOTE: It is normal for slight yellow tipping of the flames to
appear after a few minutes of operation using Propane (LP)
Gas. Orange-colored streaks in the flame are produced
from burning airborne debris; this is normal during initial
start up and should dissipate within a few minutes of
operation.
Yellow Flames:
Further adjustment is required.
®
burner ignition. Push in the burner control
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”.
3. Test reignition of the XLO and observe the carry-over
of the small simmer flames as the XLO system cycles
the burners on and off.
• If the flame performance is not acceptable it may
be necessary to readjust the valve screw for a top
burner that does not have sufficient carry-over of
the flame. Turn the valve screw very slightly
counter-clockwise until carry-over of the flame is
acceptable. (See Setting Valve Screws for the
STAR Burners).
• If the burner flame is uneven, flutters, makes
excessive noise, or lifts, some of the slots in the
burner base may be blocked with food spillage or
other debris. Clogged slots can be cleared using a
straightened paper clip, needle, or similar object.
Hard-to-remove, encrusted food or debris can
sometimes be removed using a steel wool pad or
fine wire brush.
4. 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 Tips on Outer Cones:
Normal for LP Gas
Soft Blue Flames:
Normal for Natural Gas
2. Turn valve to 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 reignite and wrap around (also
called “carry-over”) the burner within several seconds.
This flame “carry-over” is essential for proper burner
ignition and reignition.
Correct burner cap Incorrect burner cap
5. Repeat the Ignition and Flame Test procedures for
each rangetop burner.
English 7
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