Thermador SGC304R User manual

Lit. No. 90-52-056
Thermador
THE S C I E N C E O F C O O K I N G ? '
GAS COOKTOP
MODELS: S G C 3 0 4 R & SGCS304R
SGC365R & SGCS365R
SGC456R & SGCS456R
SERVICE MANUAL
Thermador
5551 MCFADDEN • HUNTINGTON BEACH, CALIFORNIA 92649 *TELEPHONE: [phone]
March, 1999

THIS M A N U A L CO NT AINS INF ORMAT IO N T HAT
IS NECESSARY FOR SERVICING THE
THERMADOR® 30" 36" & 45" GAS COOKTOPS,
MODE LS:SGC304R & SGCS304R
SGC365R & SGCS365R
SGC456R & SGCS456R
THIS MA NUA L IS DESIG NED TO BE USED O NL Y
BY QUALIF IED SERVICE PERSONNEL.
T HERMADO R R EC O MMENDS T H AT C UST O M-
ERS DO N O T SERVICE T HEIR O WN UNIT S, DUE
TO T HE CO MPLEXITY A ND T HE RISK OF H I G H -
VOLTAG E ELECTRICAL SHOCK.
THE IN FO RMAT IO N IS O RG ANIZED TO HELP THE
SERVICER EASILY FIND WHAT IS NEEDED TO RE-
PAIR THE UNIT.
Page ii

Table Of Contents
Page
General 1-1
Serial Number/Data Sticker & Diagram Locations 1-1
Symbols You Will See In The Manual 1-2
Important Safety Information 1-2
Thermador Gas Cooktop Warranty 1-3
Servicing The Components 2-1
Models SGC304R & SGCS304R Cooktop Components 2-1
Models SGC365R & SGCS365R Cooktop Components 2-2
Models SGC456R & SGCS456R Cooktop Components 2-3
Servicing The General Components 2-4
Replacing The Maintop 2-4
Replacing A Burner Base & 0-Ring 2-6
Replacing An Ignitor 2-7
Replacing A Gas Valve & Spark Switch 2-8
Replacing The Spark Module 2-10
Replacing A Jet Holder 2-12
Servicing The Simmer (XL0) Components 2-14
Replacing A Potentiometer 2-14
Replacing A Gas Solenoid 2-16
Replacing The Gas Simmer Controller 2-18
Replacing The Pilot Light 2-20
Replacing The Gas Pressure Regulator 2-22
Troubleshooting 3-1
Theory Of Operation 3-1
Strip Circuits 3-16
Simmer Controller Wiring 3-20
Simmer Controller Functions 3-22
Checking The Operating Voltages From The Simmer Controller 3 - 2 2
Testing The Components 3-23
Straightening The Cooktop 3-30
Installing The Bracket Attachment Kit 3-31
Wiring Diagrams 4-1
Page iii

NOTES -
Page iv

GENERAL
SERIAL N U M B E R / D ATA STICKER
& D I A G R A M L O C AT I O N S
DIAG RA M
(TAPED TO INS IDE OF
BURNE R BOX) SERIA L NUMB E R/ DA T A STICK ER
(LOCATED ON RICI.IT
FRONT UNDERSIDE)

SYMBOLS YOU WILL SEE IN THE MANUAL
The following symbols are provided throughout
this manual. For reasons of personal safety and
A WARNING
This symbol alerts you to such dangers as
personal injury, bums, fire, and electrical
shock.
IM POR TA NT SAFETY I N F O R M AT I O N
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.
proper operation and servicing of the cooktop,
follow the instructions carefully each time you see
one of the symbols.
A CAUTION
This symbol alerts you to actions that could
cause product damage (scratches, dents, etc.),
and damage to your personal property.
GAS C O O KT O PS- WHA T TO DO
IF YOU SMELL GAS
• D o not try to light any appliance.
• D o not touch any electrical switch.
• D o not use any phone in your building.
• Immediately c all y o ur gas s upplier fr om a
neighbor's phone.
• Follow the gas supplier's instructions.
• I f 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 sup-
plier.
THERM ADOR ASSUMES N O RESPONSIBILITY
FOR ANY REPAIRS MADE ON OUR PRODUCTS
BY ANYONE OTHER THAN AUTHORIZED
THERMADO R SERVICE TECHNICIANS.

THERMADOR® GAS COOKTOP WARRANTY
Length of Warranty Thermador will pay for Thermador will not pay for
FULL ONE YEAR WARRANTY All repair labor and replacement I. S e rv i c e by an unauthorized
For one year from date of installa-
tion or date of occupancy for a
parts found to be defective due to
materials and workmanship.
Service must be provided by a
agency. Damage or repairs
by an unauthorized agency
or use of unauthorized parts.
new previously unoccupied
dwelling, any part which fails in Factory Authorized Service Agency, 2. S e r v i c e visits to:
normal home use will be repaired during normal working hours. • Teach you how to use the
or replaced free of charge. appliance.
• Correct the installation.
Save all dated receipts or other You are responsible for
evidence of date of installation/
occupancy date. providing electrical wir-
ing and/or gas installa-
tion and other connecting
facilities.
• Reset circuit breakers or
replace home fuses.
3. D a m a g e caused from acci-
dent, abuse, alteration, mis-
use, incorrect installation or
installation not in accor-
dance with local codes, or
improper storage of the ap-
pliance.
4. Re pa i r s due to other than
normal home use.
5. A n y service visits and labor
costs during the limited
warranty.
This warranty applies to appliances used in normal family households; it does not cover their use in commercial situations.
This warranty is for products purchased and retained in the 50 states of the U.S.A., the District of Columbia, and Canada. The
warranty applies even if you should move during the warranty period. Should the appliance be sold by the original purchaser
during the warranty period, the new owner continues to be protected until the expiration of the original purchaser's warranty
period.
This warranty gives you specified legal rights. You may also have other rights which vary from state-to-state.
HO W TO OBTAI N SERVICE
We want you to be a satisfied customer. If a situation arises that has not been resolved to your satisfaction, please let us know.
Write to:
Consumer Relations Department
Thermador, P.O. Box 22129
Los Angeles, CA 90022
or phone:
[phone]
Please be sure to include the Model Number, Serial Number (located on the data sticker), and the Date of Original Purchase/
Installation.
Page 1-3

NOTES
Page 1-4

SERVICING THE COMPONENTS
The serviceable components inside the 30 ", 36",
and 45 " cooktops are included in this section of the
manual, which is divided into two parts. The first
part contains service procedures for all o f the
components t hat ar e c ommon to each o f the
cooktops. The second part contains procedures for
The serviceable c omponents inc luded i n the
SGC304R & SGCS304R Cooktops are as follows
(see the illustration for the locations):
• Maintop
• Bur ner Base
• Ignitor
• Gas Valve
• Spark Switch
MODELS SGC3041t & SGCS3041t
COOKTOP COMPONENTS
• Spark Module
• Jet Holders
• Potentiometers—SGCS304R Only
• Gas Solenoids—SGCS304R Only
• Gas Simmer Controller—SGCS304R Only
• Pilot Light—SGCS304R Only
Refer to the section on the following pages for the
component you wish to service.
BURNERBASE I G N I T O R
SPARK MODULE
GAS SIMMER CONTROLLER
Page 2-1
the XL0 (gas simmer controller) model cooktops.
Refer to the section that deals with the component
you wish to servive. The component locations for
each of the three model cooktops are shown on the
following pages.
MAINTOP
GAS SOLENOIDS
SPARK SWITCHES
& GAS VALVES
PILOT LIGHT
POTENTIOMETERS

The serv iceable c omponents inc luded i n the
SGC365R & SGCS365R Cooktops are as follows
(see the illustration for the locations):
• Maintop
• Burner Base
• Ignitor
• Gas Valve
• Spark Switch
BURNER BASE
(
4
0
,
,
MODELS SGC365R & SGCS365R
COOKTOP COMPONENTS
GAS SIMMER
CONTROLLER
SPARK MODULE
• Spark Module
• Jet Holders
• Potentiometers—SGCS365R Only
• Gas Solenoids—SGCS365R Only
• Gas Simmer Controller—SGCS365R Only
• Pilot Light—SGCS365R Only
Refer to the section on the following pages for the
component you wish to service.
IGNITOR MAINTOP
JET HOLDER
GAS SOLENOIDS
POTENTIOMETERS
PILOT LIGHT
SPARK SWITCHES
& GAS VALVES

MODELS SGC456R & SGCS456R COOKTOP COMPONENTS
The serviceable components included i n the
SGC456R & SGCS456R Cooktops are as follows
(see the illustration for the locations):
• Maintop
• Burner Base
• Ignitor
• Gas Valve
• Spark Switch
BURNER BASE IGNITOR
JET HOLDER GAS SOLENOIDS
SPARK MODULE
• Spark Module
• Jet Holders
• Potentiometers—SGCS456R Only
• Gas Solenoids—SGCS456R Only
• Gas Simmer Controller—SGCS456R Only
• Pilot Light—SGCS456R Only
Refer to the section on the following pages for the
component you wish to service.
GAS SIMMER
CONTROLLER
PILOT LIGHT
POTENTIOMETERS
SPARK SWITCHES
& GAS VALVES

This section is for servicing components that are
included i n both th e SGC and SGCS Model
SERVICING THE GENERAL COMPONENTS
A WARNING
Turn off the gas supply and the power circuit to
the cooktop at the main (house) junction box
before servicing this unit.
A CAUTION
When you work on the cooktop, be careful when
handling the sheet metal parts. There are sharp
edges present and you can cut yourself if you are
not careful.
1. T u r n off the gas supply and the electrical
power going to the cooktop.
2. R e mo v e the grates and burner caps from the
cooktop.
3. R e mo ve the knobs from the controls.
4. U s i n g a 2 5
/3 2
" ( 2 0
m m )
s o c k
e t ,
u n s
c r e
w
a
n
d
remove the venturi from each of the burner
bases,then lift the burner basesand rubber o-
rings from the maintop.
Replacing The Maintop
Cooktops. Although a 45 " model cooktop is illus
trated, the components for the 30 " and 36 " model
are the same and are serviced in the same manner.
5. S G C S Models Only: Carefully lift the front
of the maintop several inches and slide the
pilot light holder off the red lens.
PRESS PILOT LIGHT
AGAINST Barro m
OF COOKTOP AND
SLIDE OVER BASE
OF LENS
[1_PILOTLiGHTt
6. U n p l u g the ignitor wires from the ignitor
pins and remove the maintop (refer to the
nextpage for the ignitor wire connections).
COOKTOP
SURFACE LENS
IGNITOR CONNECTOR
7. U n s n a p the e-ring from the groove in each of
the ignitors, and remove the ignitors from the
cooktop.
8. U n s n a p and remove the bezels from the
maintop.
9. Reverse the previous steps and install the
new maintop.

a t i l t
45" COOKTOP
Page2-5

Replacing A Burner Base & 0-Ring
A WARNING
Turn off the gas supply and the power circuit to
the cooktop at the main (house) junction box
before servicing this unit.
A CAUTION
When you work on the cooktop, be careful when
handling the sheet metal parts. There are sharp
edges present and you can cut yourself if you are
not careful.
1. T u r n off the gas supply and the electrical
power going to the cooktop.
2. R e m o ve the grates and burner caps from the
cooktop.
3. U s i n g a 2 5
/3 2
" ( 2 0
m m )
s o c k
e t ,
u n s
c r e
w
a
n
d
remove the venturi from the burner base you
wish to replace, then lift the burner base and
rubber o-ring from the maintop.
0-RING
BOTTOMVIEW
1
1
I
F
V
E
N
T
U
R
I
dor
.,
B
U
R
N
E
R
B
A
S
E
COOKTOP
4. In s ta l l the new o-ring in the new burnerbase
and reassemble the cooktop.

A WARNING
Turn off the gas supply and the power circuit to
the cooktop at the main (house) junction box
before servicing this unit.
A CAUTION
When you work on the cooktop, be careful when
handling the sheet metal parts. There are sharp
edges present and you can cut yourself if you are
not careful.
1. T u r n off the gas supply and the electrical
power going to the cooktop.
2. R e mo ve the grates and burner caps from the
cooktop.
3. R e m o ve the knobs from the controls.
E-RING—SLIDE OUT OF
4
*
-
.
G
R
O
O
V
E
I
N
I
G
N
I
T
O
R
BODY TO REMOVE
IGNITOR
4 t
. ,
I
G
N
I
T
O
R
P
I
N
IGNITOR CONNECTOR
(SEE BELOW FOR WIRE NUMBER)
Replacing An Ignitor
4. U s i n g a 2 5
/3 2 " ( 2 0
m m )
s o c k
e t ,
uns
c r e
w
a
n
d
remove the venturi from each of the burner
bases,then lift the burnerbasesand rubber(3-
rings from the maintop.
5. C a re fu l l y lift the front of the maintop several
inches and prop i t up with a board or a
hammer handle. NOTE: The 45 " cooktop is
shown below. If you have a 30 " or a 36"
model, refer to page 2-5 for the ignitor wiring
illustration of those models.
6. U n p l u g the ignitor wire from the ignitor pin
that you wish to replace.
7. U n sn a p the e-ring from the groove in the
ignitor body and remove the ignitor from the
cooktop.
8. In s ta l l the new ignitor and reassemble the
cooktop.

Replacing A Gas Valve St Spark Switch
A WARNING
Turn off the gas supply and the power circuit to
the cooktop at the main (house) junction box
before servicing this unit.
A CAUTION
When you work on the cooktop, be careful when
handling the sheet metal parts. There are sharp
edges present and you can cut yourself if you are
not careful.
1. T u r n off the gas supply and the electrical
power going to the cooktop.
2. R e mo ve the grates and burner caps from the
cooktop.
3. R e mo ve the knobs from the controls.
4. U s i n g a 25
/3 2
" ( 2 0
m m )
s o c k
e t ,
u n s
c r e
w
a
n
d
remove the venturi from each of the burner
bases,then lift the burner basesand rubber o-
rings from the maintop.
5. C a re fu l l y lift the front of the maintop several
inches and prop i t up with a board or a
hammer handle. NOTE: Although a 45 "
cooktop is shown on the next page, all of the
cooktops use one of the two types o f gas
valves shown.
6. L i f t the spark switch and unsnap it from the
gas valve that you wish to service.
7. T o replace a spark switch:
a)Use a small-bladed screwdriver and insert
the blade into the wire removal slots of the
switch, then press in on the locking tabs of
the switch while you pull out on the wires,
and remove them.
b) Insert the wires into the holes of the new
switch so they lock in place (pull out on the
wire firmly to make sure it is locked), and
install the switch on the gas valve so the
locking collars snap over the screws on the
valve.
8. I f necessary, remove the right side panel on
the rough-in box to access the gas valves for
service.
9. T o replace a gas valve, remove the gas line
and mounting screw with rubber washer, (or
damp, depending on the type of valve that is
installed), and remove the valve.
10. Instal l the new gas valve (make sure that the
replacement valve has the same color I.D.
marking as the old one), and reassemble the
cooktop. NOTE: Make sure that you torque
the screw with rubber washer to a value of23
to 27 in-lbs, or the clamp screw to a value of
50 ±
-
5
i n
-
l b
s ,
t
h
e
n
l
e
a
k
-
c
h
e
c
k
t
h
e
g
a
s
l
i
n
e
connections before you secure the maintop.
(Refer to the "Gas Valve Color ID Charts" on
pages3-28 & 3-29 for valve specifications.)

-
II i
Ii 1
..
1
i
L
L
c
.
i
r
i
k
s
,
.
.
I_-----,
I N V v c
- -
- __,.,,........-,
0.4:0
,,
ites
R E M O V
A B L E
1 A
.
I n
g t
K
l
a
S
I
D
E
P
A
N
E
L
I M O
r
i n i
VALVE SCREW WITH
RUBBER WASHER
(TORQUE = 23/27 IN-LBS)
Pf
LOCKING I
COLLAR i
SHOULDER
SCRE W-
J
, I
SPARKSWITCH
0
7
-
0
(
,
ROTATE SWITCH
OPENING TO FIT
OVER SHAFT
1k
LOCKING
i CO LLAR
SHOULDER
SCREW
INSTALL SPARK SWITCHES ON GAS
VALVES-MAKE SURE THE TWO
LOCKING COLLARS LOCK OVER
THE SHOULDER SCREWS

A WARNING
Turn off the gas supply and the power circuit to
the coolctop at the main (house) junction box
before servicing this unit.
A CAUTION
When you work on the cooktop, be careful when
handling the sheet metal parts. There are sharp
edges present and you can cut yourself if you are
not careful.
1. T u r n off the gas supply and the electrical
power going to the cooktop.
2. R e m o v e the grates and burner caps from the
cooktop.
3. R e m o v e the knobs from the controls.
4. U s i n g a 2 5
/ 3 2
" ( 2 0
m m )
s o c k
e t ,
u n s
c r e
w
a
n
d
remove the venturi from each of the burner
bases, then lift the burner bases and rubber o-
rings from the maintop.
[ BOTTOM V
I
EW
C
7
I
N
G
1
Replacing The Spark Module
5. C a ref u l ly lift the front of the maintop several
inches and prop it up with a board or a
hammer handle.
6. R e m o v e the two screws and shoulder wash-
ers from the connector and unplug it from the
spark module.
7. U n p l u g the ignitor wires from the other end
of the spark module.
8. R e m o v e the screw and flat washer from the
spark module and unhook it from the tab in
the burner box, then remove the module.
9. I n s t a l l the new spark module, and reassemble
the cooktop. NO TE: The illustrations show
spark ignitor wire terminals for the 45 "and
the 36" cooktops. The 30 "cooktop wires are
connected to terminals 31, 32, 33, & 34, as
shown in the 36" model wiring illustration.

CONNECTOR
SCREWS & WASHERS
9-WIRE CONNECTOR
SPARK MODULE
SCREW & WASHER
45" Models
CONNECT NUMBERED
IGNITOR WIRES TO
- S P ARK MODULE TERMINALS
39 37
1
0
0
4
0
P I P - 1
1
1
1 °
'
In•
. . 0 0
0
- -
i t t r
e t , -
-
.
011
1
- 1 1
1 . 1
111
1
d o o l o
o p .
. d
o m
m t
p
p
m
"
41 :38
36 At
TAB ON BURNER BOX
FITS INTO END SLOT
SECURE CONNECTOR TO MODULE
WITH SCREWS AND WASHERS
8-WIRE CONNECTOR
MOUNT MODULE TO ROUGH-IN
BOX WITH SCREW & WASHER
30" & 36" Models
SLIDE SPARK MODULE SO TABS
ON BURNER BOX FIT INTO END SLOTS
0

A WARNING
Turn off the gas supply and the power circuit to
the coolctop at the main (house) junction box
before servicing this unit.
A CAUTION
When you work on the cooktop, be careful when
handling the sheet metal parts. There are sharp
edges present and you can cut yourself if you are
not careful.
1. T u r n off the gas supply and the electrical
power going to the cooktop.
2. R e m o v e the grates and burner caps from the
cooktop.
3. R e m o v e the knobs from the controls.
Replacing A Jet Holder
4. U s i n g a 2 5
/ 3 2
" ( 2 0
m m )
s o c k
e t ,
u n s
c r e
w
a
n
d
remove the venturi from each of the burner
bases, then lift the burner bases and rubber °-
rings from the maintop.
5. C aref u l l y lift the front of the maintop several
inches and prop it up with a board or a
hammer handle. NO T E: Although a 45 "
model cooktop is shown, the jet holders are
serviced the same for the 30" and 36 "models.
6. R e m o v e the gas line from the jet holder you
wish to replace.
7. R e m o v e the mounting nut from the jet holder
and remove the jet holder from the support
bracket.
8. I n s t a l l the new jet holder (make sure that the
replacement jet holder has the same color
marking as the old one), and reassemble the
cooktop. NO TE: Mak e sure that y ou leak-
check the gas line connections before y ou
secure the maintop. (Refer to "Jet Holder
Color I.D. Chart" on page 3-29 for jet holder
specifications.)