Thermador Pro Harmony PRL364GDH/01 User manual

SERVICE MANUAL
Thermador
Pro Harmony®
Range
Model: PRL364GDH/01

Service Manual for the Thermador Pro Harmony Range, Model PRL364GDH/01
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TABLE OF CONTENTS
1General.......................................................................................4
1.1 Technical Documents to Read Prior to Servicing ........................... 4
1.2 Wiring Diagram................................................................................ 4
1.3 Data Rating Plate............................................................................ 4
1.4 Recommended Tools and Supplies................................................ 5
1.5 Important Safety Information........................................................... 5
1.5.1 Safety Symbols Used In This Manual..................................... 5
1.5.2 Safety Precautions to Know Prior to Servicing ....................... 5
2Operation ...................................................................................8
2.1 Control Knobs.................................................................................. 8
2.1.1 ExtraLow Feature.................................................................... 8
2.1.2 Griddle Control Knob............................................................... 8
2.1.3 Temperature Selector Knob.................................................... 9
2.1.4 5-Position Oven Function Selector Knob................................ 9
2.2 Automatic Re-Ignition...................................................................... 9
2.3 Operation during a Power Outage .................................................. 9
2.3.1 Cooling Fan –Automatic Operation.......................................... 9
2.4 Burner Assembly and Maintop Components ................................ 10
3Testing, Setting, Troubleshooting - Burners and Ignition....10
3.1 Before Testing...............................................................................10
3.1.1 Oven Temperature Testing.....................................................10
3.2 Burner Characteristics................................................................... 11
3.2.1 Flame Characteristics............................................................ 11
3.3 Testing Burner Ignition..................................................................12
3.3.1 Testing Cooktop Burner Ignition............................................12
3.3.1.1 Testing the HI Setting........................................................12
3.3.1.2 Testing the SIM Setting.....................................................12
3.3.1.3 Testing the XLO Setting.................................................... 12
3.3.2 Testing Bake Burner Ignition.................................................12
3.3.3 Testing Broil Burner Ignition..................................................12
3.4 Manually Setting Burner Valves....................................................12
3.4.1 Tools Needed........................................................................ 12
3.4.2 Adjusting the Bypass Screws................................................ 12
3.5 Burner, Flame, and Ignition Troubleshooting................................13
3.5.1 Cooktop Burners –Burner and Flame Diagnostics...............13
3.5.1.1 Uneven Flame Distribution & Flame Noise Diagnostics ...13
3.5.2 Ignition Diagnostics ............................................................... 14
4Oven Light Diagnostics ..........................................................16
5Fault Codes..............................................................................17
6Service and Repair..................................................................19
6.1 Preparing the Range for Servicing................................................19
6.2 Accessing Components under the Maintop .................................. 19
6.2.1 Removing Knobs, Grates, Griddle, and Burner Assemblies. 19
6.2.2 Removing the Maintops.........................................................21
6.2.3 Removing the Heat Shield.....................................................22
6.2.4 Griddle Removal and Replacement ......................................22
6.2.5 Burner Support Rail Removal and Replacement..................25
6.3 Removal and Replacement of Top-Accessible Components........27
6.3.1 Jet Holder Assembly Removal and Replacement.................27
6.3.2 Manifold Removal and Replacement.................................... 28

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6.3.3 Standard Valve Removal and Replacement.........................30
6.3.4 Microswitch Removal and Replacement............................... 31
6.3.5 Solenoid Valve Removal and Replacement..........................32
6.3.6 XLO Valve Removal and Replacement................................. 33
6.3.7 Potentiometer Removal and Replacement ...........................35
6.3.8 Temperature Selector Removal and Replacement............... 36
6.3.9 5-Position Oven Function Selector –Removal and
Replacement.........................................................................................37
6.3.10 Dual Valve Removal and Replacement ................................38
6.3.11 Regulator Removal and Replacement.................................. 39
6.3.12 Ignition Device Removal and Replacement..........................40
6.3.13 LED Indicator Removal and Replacement............................40
6.3.14 Control Board Removal and Replacement ...........................41
6.3.15 Simmer Control Board Removal and Replacement..............42
6.4 Removal and Replacement of Back-Accessible Components......43
6.4.1 Backguard and Island Trim Removal and Replacement....... 43
6.4.2 Back Panel Removal and Replacement................................44
6.4.3 Terminal Block Removal and Replacement.......................... 45
6.4.4 Electrical Wiring Connections at the Terminal Block ............45
6.4.5 Cooling Fan Removal and Replacement ..............................45
6.4.6 Broil Burner Assembly Removal and Replacement.............. 47
6.4.7 Convection Components –Removal and Replacement....... 49
6.5 Removal and Replacement of Front-Accessible Components ..... 52
6.5.1 Control Panel Removal and Replacement............................52
6.5.2 Bake Burner Components –Removal and Replacement..... 54
6.5.3 Oven Temperature Sensor Removal and Replacement.......58
6.5.4 Oven Lamp Removal and Replacement............................... 59
6.5.5 Door Removal and Installation..............................................60
6.5.5.1 Removing the Door ...........................................................60
6.5.5.2 Installing the Door .............................................................60
6.5.6 Door Handle Components - Removal and Replacement......60
6.5.6.1 Removing Door Handle Components ...............................61
6.5.6.2 Installing Door Handle Components .................................61
6.5.7 Door Gasket Removal and Replacement..............................61
6.5.8 Kick Panel Removal and Replacement.................................62
6.5.9 Bottom Plate of Front Frame –Removal and Replacement.63
6.5.10 Door Hinge Receiver Removal and Replacement ................64
6.5.11 Door Hinge Removal and Replacement................................65
6.5.12 Thermostat Removal and Replacement................................66
7Before Returning Appliance to Service .................................67
8Clean-Up ..................................................................................67
9Additional Resources..............................................................68
9.1 QuickFinder...................................................................................68
9.2 Technical Support ......................................................................... 68

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1 GENERAL
This manual contains information that is necessary for servicing the
following Thermador Pro Harmony Range:
PRL364GDH/01
Due to the complexity and the risk of high-voltage electrical shock,
customers should not service their appliances. The information
provided in this document is intended for trained, qualified personnel
only. The proper function and the safety of the appliance can be
affected by an improper repair, and even serious threats to life or
physical condition may arise. BSH Home Appliances Corporation is
not liable for damages caused by improper repairs performed by
unauthorized parties. Local codes and standards apply and must be
observed.
For authorized servicers, additional assistance is available by
contacting Technical Support at [phone]
1.1 Technical Documents to Read Prior to Servicing
Before you start servicing, check QuickFinder for all other technical
documents associated with this specific appliance.
1.2 Wiring Diagram
The Wiring / schematic diagram is located behind the kick panel
(see Figure 1).
1.3 Data Rating Plate
The data rating plate which shows the model, serial, and FD number
is located underneath the control panel, as shown in Figure 1. This
information is required when calling for technical or customer service.
The first two digits of the FD number indicate the year the appliance
was produced. To get the year, add 20 to the first two digits (for
example, an FD number beginning with 87 was produced in 2007; a
number that begins with 88 was produced in 2008). The last 2 digits of
the FD number indicate the month the product was produced (for
example, 06 indicates the appliance was produced in June).
Figure 1: Data Rating Plate and Wiring Diagram Locations

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1.4 Recommended Tools and Supplies
The following tools and supplies are recommended to use when
servicing this appliance:
Caution
Power Drivers
■If using a power driver, set the clutch to the lowest setting
Driver sizes: T-10, T-20, T-25, T-30
1/4 inch nut driver or 1/4 inch socket wrench / ratchet
Wrench sizes: 1/2 inch, 1/4 inch, 5/16 inch, 11/32 inch open-end
Socket wrench / ratchet 11/32 inch
Swivel head driver with an 11/32 inch, deep-well socket
Large nut driver (1 inch min.) with a deep-well socket
Long, hand-held T-20 driver
Adjustable wrench
Pipe wrench
Precision screwdriver with a high-strength blade, 1/8-inch
(3.0 mm) wide, .020-inch (0.50 mm) thickness tip
Flat blade screwdrivers: large, small
Slip joint pliers
Needle-Nose pliers
Hook or non-straight hex key (Allen wrench)
Protective gloves
Gas leak test equipment
Pipe sealant
Small mirror
Protective eye wear (such as glasses or goggles)
Flashlight
Amp meter
Thermometer with thermocouple leads
Multimeter
Air lifter / air dolly
1.5 Important Safety Information
Before starting to service an appliance, familiarize yourself with all
safety information and precautions contained in this manual.
1.5.1 Safety Symbols Used In This Manual
This symbol alerts you to dangers that may result in bodily injury or
death.
Caution
This symbol alerts you to actions that may result in damage to the
product, or property.
1.5.2 Safety Precautions to Know Prior to Servicing
Before You Start Servicing the Appliance
Before disassembly, removal or installation of any component, do the
following:
■Turn off electrical power by removing the power cord from the
electrical outlet, and putting the circuit breaker in the OFF position
or by removing the fuse.
■Turn off the gas supply to the appliance.
■Make sure grates and burner assemblies are cool before
removing them.

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Replacement Parts
Use only authorized replacement parts per catalog for this appliance.
Use of substitutions may defeat compliance with safety standards set
for home appliances, will void the warranty, and may create safety
hazards resulting in bodily injury, death, or damage.
Fire / Explosion Hazards
■Make sure the gas valve at the wall is closed before removing and
installing any gas components.
■Do not store or use any flammable vapors, liquids, or combustible
materials in the vicinity of this appliance.
■Do not use water on grease fires. Turn appliance off and smother
the fire with baking soda or use a dry chemical or foam-type
extinguisher.
Griddle Hazard
■The griddle plate must always be correctly in place when the
griddle is turned on.
What to Do If You Smell Gas
■Do not try to light any appliance
■Do not touch any electrical switch
■Do not use any phone or cell phone in the building
Installation and service must be performed by a qualified installer,
service agency, or the gas supplier.
Testing for Gas Leaks
■Do not ever use a flame to test for gas leaks, as doing so may
result in explosion, injury, death, and/or damage to the appliance
and property.
■With electrical power off, carefully check for gas leaks at each gas
component that was removed, replaced, or otherwise serviced
using a gas leak detector or bubble test.
Electrical Hazards
■Before servicing the appliance, remove electrical power by
disconnecting the power cord from the wall receptacle, by shutting
off the circuit breaker, or by disconnecting the proper fuse.
■If tests have to be conducted while the appliance is live, always
use a residual-current-operated circuit-breaker. The protective
conductor connection must not exceed the recommended values.
■When repairs are complete, perform a function test in accordance
with the appropriate regulations.
■Do not under any circumstances cut or remove the separate
ground wire or the third (ground) prong from the power cord plug.
■Improper grounding or reverse polarization will cause malfunction
(such as continuous sparking of the igniters), which can damage
the appliance and create an electrical shock hazard. Make sure
the circuit is properly grounded and polarized in accordance with
applicable local codes and ordinances. Receptacle replacement
shall be in accordance with the National Electric Code.
Hot Surfaces
To avoid burns and injury, do not handle components and surfaces
that are hot, such as the cooktop burners, infrared broil burner, bake
burner, heat deflector, and interior oven surfaces.

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In Case of Power Outage
1. If for any reason a control knob is on when there is any failure or
removal of electrical power from the appliance (such as a power
outage), immediately turn all control knob(s) to the OFF position.
2. Ventilate by opening a door or window, and wait at least 5minutes
for all the gas to dissipate.
3. If you smell gas, refer to the applicable safety precautions stated
in this manual.
Sharp Components
This appliance has sheet metal and other components which often
have sharp edges. When working on this appliance, avoid cutting
yourself and other injury by handling these parts with care and using
adequate protective measures, such as gloves.
Clean-up Hazards
Don’t allow any cleaning or polishing solutions/compounds,
disinfectants or bleaches to remain in contact with the stainless steel
surfaces for long periods, or after clean-up. These may contain
chemicals or materials which could release harmful inhalants and can
damage the appliance. After cleaning or polishing, always rinse the
cleaning/polishing materials with clear water and wipe dry with a clean
soft, non-abrasive cloth.
Fiberglass Insulation
Wear gloves when handling fiberglass insulation.
Prior to Returning Appliance to Service
Prior to returning the appliance to service, make sure that:
■All electrical connections are correct and secure
■All safety grounds (internal and external) are correctly and
securely connected
■All gas connections are secure and have been leak tested using a
gas leak detector or bubble test.
■All panels and components are properly and securely
reassembled
Caution
Code Compliance
Local codes vary. Installation, electrical connections, gas connections,
and grounding must comply with all applicable codes.
TESTED IN ACCORDANCE WITH ANSI
Z21.1, THE STANDARD FOR HOUSEHOLD
COOKING GAS APPLIANCES. IN CANADA
TESTED IN ACCORDANCE WITH
CAN/CGA1.1 –M81, THE STANDARD FOR
DOMESTIC GAS RANGES.
Check your local building codes for the proper
method of installation. In the absence of local
codes, this unit should be installed in accordance
with the National Fuel Gas Code No. Z223.1/
NFPA 54 current issue and the National
Electrical Code ANSI/NFPA No. 70 current issue
or the Can –B149 Installation Codes for Gas
Burning Appliances and C22.1 Canadian
Electrical Code Part 1.
It is the responsibility of the owner and the
installer to determine if additional requirements
apply in specific installations.

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2 OPERATION
2.1 Control Knobs
The control knobs for each of the burners are located on the control
panel, with an icon to identify the location on the range (see Figure 2).
The left-most front and left-most rear burners have the ExtraLow
(XLO) feature.
Figure 2: Burner Control Knobs
1. Press a control knob in, and turn counter-clockwise to HI setting.
The igniter for the burner clicks while sparking until flame ignition.
Burner should ignite within 4 seconds.
2. For the non-XLO burners, rotate the knob to any setting between
HI and SIM. For the XLO (left front and left rear) burners, rotate
the knob to any setting between HI and XLO.
NOTE: The blue LED indicator lights up when burners are lit.
2.1.1 ExtraLow Feature
When the knob is set to XLO - the very lowest setting, the flame
cycles on for approximately 8 seconds and then turns off for 52
seconds of each minute.
The knob can also be set between SIM and XLO for a variable range
of low heat, with the flame cycling on and off at a different frequency
than the XLO setting (see Figure 3).
Figure 3: XLO Settings
2.1.2 Griddle Control Knob
The griddle knob controls the temperature to the griddle, from 150° F
to 500° F (see Figure 4).
There are no fixed settings on the knob. Press and turn the knob
clockwise to select a setting.
Figure 4: Griddle Control Knob

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2.1.3 Temperature Selector Knob
For each oven, use the respective Temperature Selector knob
(see Figure 5).
Figure 5: Temperature Selector Knob
2.1.4 5-Position Oven Function Selector Knob
Use this knob for oven bake, extended bake (Sabbath mode),
convection bake, and broil (see Figure 6).
Figure 6: 5-Position Oven Function Selector Knob
2.2 Automatic Re-Ignition
Each burner has its own electronic igniter that sparks when the burner
is turned on. If one or more burner blows out, the respective
igniter/electrode automatically re-ignites the flame.
2.3 Operation during a Power Outage
When there is a removal of electrical power, the XLO burners cannot
be used. Do not attempt to light them manually.
Caution
Power Outage Precautions
■Ventilate well by opening a door or window, and wait at least five
minutes until all the gas dissipates.
■If you smell gas, comply with the warnings and precautions in the
Important Safety Information section (page 5) of this manual.
2.3.1 Cooling Fan –Automatic Operation
Cooling Fan - Automatic Operation
■Pro Range equipped with original control part # 00649291
The cooling fan energizes when the oven cavity reaches 425 Deg F.
During cool down the fan de-energizes when the cavity cools to 375 Deg F.
■Pro Range equipped with replacement control part # 00709785
The cooling fan energizes when the oven cavity reaches 300 Deg F.
During cool down the fan de-energizes when the cavity cools to 250 Deg F.
Part # 00709785 is standard on most Pro Ranges FD # 9112 and later

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2.4 Burner Assembly and Maintop Components
Figure 7: Burner Assembly and Maintop Components
3 TESTING, SETTING, TROUBLESHOOTING -
BURNERS AND IGNITION
Servicing Burners and Ignition
■Burner and ignition servicing must be performed by a qualified
technician.
■Improper adjustments may be dangerous, cause damage or
harmful by-products, and may void the appliance warranty.
Ignition Hazard
Do not touch burners when the igniters are active (sparking).
3.1 Before Testing
Before testing the burners and ignition, do the following:
1. Reinstall any loose components that may have been removed
earlier, such as burner caps, griddle, and grates. Be certain that
burner caps seat properly into the burner bases, burner pedestal
and Venturi tube are aligned correctly, and that the ignition wires
are properly positioned.
2. To test for gas leaks, make sure the electrical power is removed
and the manual gas shut-off valve is open, and then carefully
check range components and gas supply for leaks using a gas
leak detector or bubble test.
3. After gas checks are complete and before testing, connect the
range to the electrical power supply.
3.1.1 Oven Temperature Testing
**Do not remove the thermocouple prematurely when the oven is hot.
Test oven temperature using a thermometer with a thermocouple
lead. If you leave the thermocouple in the oven during a speed
clean cycle, keep in mind it will take a few hours before the oven
is cool enough to retrieve the thermocouple.
Convection Bake
For convection bake, you can visually inspect if the convection fan
is working. The convection fan only works after the preheating
finishes, thus it may take less time to test the convection fan on
the lowest bake convection setting.