Thermador STARNGKIT User manual

CONVERSION INSTRUCTIONS
Propane Gas to Natural Gas Conversion Kit
ForThermador Professional®Cooktops and Ranges
Model STARNGKIT Part No. 35-00-679
Contains 7mm Hex Main Orifices
This kit is used to convert only Professional Model PCS Professional®Cooktops
and Model PRDS Professional®ranges from propane gas to natural gas operation.
This kit cannot be used to convert olderThermador Professional®cooktops or
ranges, nor any other brand of appliance.
PLEASE READ ENTIRE INSTRUCTIONS BEFORE PROCEEDING.
MODEL GP24WK AND PCS484WK WOK COOKTOPS REQUIRE A SEPARATE KIT
TO CONVERT THE WOK. ORDER WOKNGKIT, PART NUMBER 35-00-611.
COMPLETE THIS CONVERSION PRIOR TO INSTALLING 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.
OWNER: Please retain these instructions for future reference.
WARNING: Disconnect gas and electric power
before making conversion. Before turning power ON,
be sure that all controls are in the OFF position.

PAGE 2
Replace Main
Range Orifice for
Model Gas Surface Convert Convert
Number Burners Grill Griddle
COOKTOPS
PCS364GD Step 3 (4 each #168/1.68mm) -------- Step 5
PCS364GL Step 3 (4 each #168/1.68mm) Step 4 --------
PCS366 Step 3 (6 each #168/1.68mm) -------- --------
PCS484GG Step 3 (4 each #168/1.68mm) Step 4 Step 5
PCS484WK Step 3 (4 each #168/1.68mm) -------- --------
PCS486GD Step 3 (6 each #168/1.68mm) -------- Step 5
PCS486GL Step 3 (6 each #168/1.68mm) Step 4 --------
RANGES
PRDS304 Step 3 (4 each #168/1.68mm) -------- --------
PRDS364GD Step 3 (4 each #168/1.68mm) -------- Step 5
PRDS364GL Step 3 (4 each #168/1.68mm) Step 4 --------
PRDS366 Step 3 (6 each #168/1.68mm) -------- --------
PRDS484GG Step 3 (4 each #168/1.68mm) Step 4 Step 5
PRDS486GD Step 3 (6 each #168/1.68mm) -------- Step 5
PRDS486GL Step 3 (6 each #168/1.68mm) Step 4 --------
TABLE 2: Conversion Steps by Model Number
Complete steps 1 and 2 for all cooktops and ranges,then follow additional steps as
identified below for each particular model
Tools/ Parts Required:
• Socket Driver - 1/4" Drive,
3"minimum extension
• 1/2" Open end Wrench
• Screwdriver
• 1/2" Deep Well Socket
• 1" Open end Wrench
TABLE 1: Natural Gas Conversion Kit Contents
Description Part Number Ouantity
Instructions, Natural Gas Conversion 15-13-106 1
#168 Natural Gas Orifice, Surface Burner 15-12-591-01 6
7mm Hex Socket 20-02-306 1
Foam Tape, 1" 20-02-059
Plastic Bag 19-09-387 1
Carton 19-08-542 1
Gauge, Orifice Setting 15-12-209 1
* The Conversion Kit contains the indicated quantities of parts.How-
ever, some parts will not be used depending upon the model being
converted. Refer to Table 2 for a listing of parts to be used and
installation steps to follow for each particular model number.

PAGE 3
PROCEDURE TO CONVERT FROM PROPANE GAS TO NATURAL GAS
FOLLOW STEPS 1 AND 2 FOR ALL COOKTOPS AND RANGES,
THEN FOLLOW ADDITIONAL STEPS AS IDENTIFIED IN TABLE 2
FOR THE PARTICULAR MODEL BEING CONVERTED.
STEP I: TURN OFF GAS AND ELECTRICITY If the appliance is in-
stalled:Shut off the gas valve to the appliance and remove appliance
power cord from electrical outlet or turn breaker off at breaker
box.
STEP 2: CONVERT PRESSURE REGULATOR FROM 10" W.C.TO
10" W.C. The gas pressure regulator supplied with the unit is
convertible from propane gas to natural gas. For cooktops, the
regulator is mounted external to the appliance. For ranges, the
regulator is mounted beneath the spill tray on the far left side.To
access the range regulator, remove the aluminum Trim Strips from
the spill tray sides (see Fig. 1A). Using the screwdriver, place it
approximately 3" from either end of the trim, parallel to the spill
tray surface so you can slide the screwdriver tip under the trim
edges to lift up for removal.To remove spill tray,loosen and remove
burner nut using 1" wrench as shown in Fig. 1B. Remove burner
bases and disconnect wire to igniter. Remove spill tray and heat
shield to access regulator. Reassemble in reverse order. Before you
can reassemble spill tray trim, you must readjust all of the lancing
on the trim. This will secure the trim (see Fig. lC). To operate
correctly on natural gas, the pressure regulator must be converted
as follows (see Fig. 1).
a) REMOVE THE CAP from the top of the regulator.
b) TURNTHE CAP OVER,so that the letters“NAT” can now be
seen upright in the cap.
c) REPLACE THE CAP into the top of the regulator, seating it
firmly.Twist cap clockwise to lock in place. Make certain the
spring located under cap remains in place.
d) Finally, REMOVETHE FOIL CONVERSION STICKER next to
the rating plate, located on bottom corner of rough-in-box
(cooktop) or behind the removable kick panel (ranges).
FIGURE 1B
FIGURE 1
NG
Cap Position
for Natural Gas

PAGE 4
The burner flame should be blue
in color and stable with no exces-
sive noise or sputtering. It should
burn completely around the
burner cap.
Foreign particles in the gas line
may cause an orange flame during
initial use. This should disappear
with use.
If the flame does not burn evenly
all the way around the burner cap,
read “What to do if you smell
Gas,” inside front cover of
Cooktop/Range Installation In-
structions.
STEP 3: CONVERT SURFACE BURNERS (ALL MODELS)
A) REPLACE MAIN ORIFICES
1) REMOVE GRATES, BURNER CAPS and FLAME SPREADERS (see Fig. 2).
2) REMOVE MAIN SURFACE BURNER ORIFICES. ( 7mm Hex) This kit con-
tains the orifices and the socket required to remove them. A method of
retaining main orifices in the socket during extraction and insertion is to
apply a piece of foam tape, supplied in the kit, to the socket, as shown in Fig.
3. Insert the socket driver with 3" minimum extension into the jet holders
and remove existing orifices, as shown in Fig. 4.
3) INSTALL NEW MAIN SURFACE BURNER ORIFICES #168. Tighten ori-
fices until snug.
4) REASSEMBLE. Install flame spreaders and burner caps (See Fig. 8). Replace
grates.
B) CONVERT VALVES FOR NATURAL GAS
The bypass jet on each valve (see Fig. 5) must be adjusted as follows:
1) With all KNOBS IN “OFF” POSITION, REMOVE KNOBS.
2) LOCATE HOLE on control panel which is aligned to bypass screw. (see Fig.
5)
3) Insert screw driver in hole. TURN Bypass SCREW clockwise until “bot-
tomed out” (approximately 1/8 to3/16 turn),then back out (counter clock-
wise) 1/2 to 3/4 turn. See Fig 5A.
4) REPLACE KNOBS.
5) CHECK FOR PROPER FLAME CHARACTERISTICS - Flame should be blue
and stable with no yellow tips on the ends of the flame. See Fig. 6.
FIGURE 2 Burner Cap
Burner Base
Flame
Spreader
Star Grate (TopView)
168
FIGURE 6

PAGE 5
STEP 4: CONVERT GRILL (MODEL NOS. PCS364GL, PCS484GG, PCS486GL, PRDS364GL, PRDS484GG, and
PRDS486GL).
a) REMOVE the grill grate, briquette pan, ceramic briquettes and the U-shaped burner. (Use extreme
caution around the ceramic grill ignitor, it is very fragile). (See Fig. 7)
b) USE A 1/2" DEEP WELL SOCKET (with counter-clockwise rotation) to loosen the grill burner orifice
hood. The orifice is located on the safety valve which is mounted on the front chassis panel. Set the
spacing between the rear of the orifice hood and the safety valve body using the guage provided in the
kit
. See Fig. 8.
c) REASSEMBLE THE GRILL in reverse order.
d) Reset grill bypass jet for proper low rate operation.Verify that the jet is screwed into the valve body
until bottomed out (This is normally done when converting to LP).Then unscrew the jet back out one
(1) full turn.
e) CHECK FOR PROPER FLAME CHARACTERISTICS – Flame should be blue and stable with no yellow
tips. Flame height should be approximately 1/4".
STEP 5: CONVERT GRIDDLE (MODEL NOS. PCS364GD, PCS484GG, PCS486GD, PRDS364GD, PRDS484GG,
and PRDS486GD).
a) COVER
THE BULLNOSE AND SIDE TRIMS TO PREVENT DAMAGE. LIFT THE REAR OF THE
GRIDDLE
PLATE ASSEMBLY FIRST, then lift the front and slide the griddle plate carefully to the rear.(If
the appliance is equipped with a backguard, cover the backguard to protect it during removal and
reinstallation of griddle plate. Use extreme care around the ceramic griddle ignitor; it is very fragile.)
b) REMOVE THE GRIDDLETHERMOSTAT BULB from beneath the griddle plate by sliding it out gently.
c) REMOVE THE SCREW SECURING THE GRIDDLE BURNER, then remove the burner.
d) USE A 1/2" DEEP WELL SOCKET (with counter-clockwise rotation) to loosen the griddle burner ori-
fice hood. The orifice is located on the safety valve which is mounted on the front chassis panel. Set the
spacing between the rear of the orifice hood and the safety valve body using the guage provided in the
kit. See Fig. 8.
e) REASSEMBLE THE GRIDDLE in reverse order.
f) CHECK FOR PROPER FLAME CHARACTERISTICS - Flame should be blue and stable with no yellow
tips. Flame height should be approximately 3/4".
FIGURE 8
GUAGE
Safety
Valve
Unscrew orifice hood
from LP Position
Insert guage, gently
screw orifice hood down
against guage.
➞
➞
➞
GUAGE
➞

Thermador reserves the right to change specifications or design without notice. Some models are certified for use in
Canada. Thermador is not responsible for products which are transported from the United States for use in Canada.
Check with your local Canadian distributor or dealer. Thermador, 5551 McFadden Avenue, Huntington Beach, CA
92649.
5551 McFadden Avenue, Huntington Beach, CA 92649 • 800/735-4328
RO8585KIT • 15-13-106A • © Thermador 1998 • Litho U. S.A. 11/00