HESTAN AGCKPB-NG (01) PDF Document

This conversion kit must be installed by a qualified service agency in accordance with the manufacturer’s instructions and all applicable codes. If the information is not followed exactly, a fire, explosion, or production of carbon monoxide may result, causing property damage, personal injury, or loss of life. The installation is not complete until the operation of the converted appliance is checked as specified in the manufacturer’s instructions.

The instructions must be performed by a qualified service technician only. The power burner must be completely cool. Before proceeding, shut off or remove the gas supply to the appliance prior to disconnecting the electrical power.

Be aware that some parts inside the power burner have sharp edges. Wear gloves when handling components to avoid personal injury.

If you smell gas, follow these steps:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Remove cover.

4. If the odor continues, keep away from the appliance and immediately call your gas supplier or your fire department.

1. Do not store or use gasoline or other flammable liquids or vapors in the vicinity of this or any other appliance.

2. An LP cylinder not connected for use shall not be stored in the vicinity of this or any other appliance.

KIT CONTENTS:

• Orifices (center burner)

• Orifice (outer burner)

• Valve (outer burner)

• Instructions

• Label

TOOLS REQUIRED:

• Work gloves

• Safety glasses

• Phillips screwdriver

• Locking pliers

• Thread sealant

• 9/32″ OR 7mm deep socket wrench or nut driver

• Miscellaneous wrenches – 7/16, 1/2, 9/16, 5/8, etc.

1. Preparation: This procedure is much easier if the appliance is completely removed from the enclosure (island). Disconnect the gas and electrical before proceeding.

2. Remove Exterior Parts: Remove the grate cover, cooking grates, and drip tray. Then, remove the control knobs and the 4 Phillips head screws securing the control panel to the unit.

3. Disconnect Control Panel: Carefully tilt down the control panel and disconnect the wiring to the light switch and the LED light bar. Remove the control panel completely. It is highly recommended to take a photo or label each wire terminal on each microswitch for each valve before proceeding.

4. Remove Octagonal Burner: First, remove the burner cap from the center burner and the small cover at the rear of the burner. Also, remove the 2 screws securing the burner to the rear wall. Tilt the burner up and out of the unit. Be careful not to damage the spark igniter next to the burner.

5. Access Manifold: Flip the entire unit over and place it on a protected surface. Using a 5/8″ wrench, disconnect the flex hose nut at the end of the left valve. You can leave the hose attached to the elbow.

6. Remove Main Orifice: Use locking pliers to keep the elbow from rotating while you use a 1/2″ wrench to remove the orifice. The locknut below the orifice must remain tight against the sheet metal.

7. Remove Manifold Pipe: Remove the three (3) nuts at the locations shown using a 7/16″ wrench. Carefully remove the manifold, being careful not to bend, kink, or snag the attached flex hoses and wires.

Converting the Regulator (NG to LP is shown):

1. With the manifold removed, you have access to the regulator. Remove the regulator cap. Use caution as there is a small spring inside.

2. Under the cap is a small plastic spring guide (usually colored blue). Unscrew this part.

3. Flip the plastic part over and re-install it in the cap.

4. Re-install the cap into the regulator.

Changing the Valve:

1. Using an adjustable wrench or locking pliers, unscrew the left valve from the manifold.

2. Before installing the new valve, apply a very small amount of thread sealant to the threads. DO NOT allow any sealant to get inside the valve.

3. Screw the new valve into the pipe using the same number of turns as the original valve to maintain a gas-tight fit. Line up the valve stem so the knob will go back on straight.

Changing the Main Orifice:

1. Install the new orifice slowly to avoid cross-threading. Consult the orifice size table for identification.

2. Use locking pliers to prevent the elbow from rotating as you tighten the orifice.

3. Ensure the locknut is tight against the sheet metal, and the orifice is screwed on until it is touching or almost touching the locknut.

Changing Center Burner Orifices:

1. With the unit upright, reach inside to hold up the orifice holder against the underside of the burner bowl to prevent it from falling.

2. Remove the 2 Phillips head screws securing the brass burner base.

3. Temporarily reinstall the 2 screws back onto the orifice holder so it doesn’t fall. You can now change the orifices without disconnecting the flex hoses.

4. Use a 9/32″ (or 7 mm) nut driver or deep socket wrench to remove the two orifices from the orifice holder.

5. Install the new orifices and remount the brass burner base in the same manner it was removed. The orifice sizes are stamped on them.

1. Re-install Manifold: Re-install the manifold and tighten the 3 nuts securing it inside the unit. Re-install any flex hoses you removed earlier (thread sealant is not needed on flex hose connections). Tighten everything well with even hand pressure.

2. Secure Wires: Reconnect any interior wires you may have disconnected. Make sure the wire harness is tucked neatly to one side and secured with wire management clips, away from hot metal surfaces. Wires and hoses must not interfere with the drip-pan when re-installed.

3. Flip Unit: Once all inside components are re-installed and secure, you can flip over the unit again.

4. Re-install Octagonal Burner: Great care should be used. It must be correctly centered and secured on the main orifice. Once re-installed on the orifice and the rear bracket is secured with the 2 screws, the burner should rest flat and have no side-to-side movement. Ensure the spark igniter almost touches the burner.

5. Final Parts: Re-install the center burner cap and cooking grates.

6. Leak Test: PROCEED TO THE LEAK TESTING SECTION OF THIS MANUAL BEFORE RE-INSTALLING THE CONTROL PANEL, KNOBS, ETC.

NG is 7″ SUPPLY -> 4″ AT MANIFOLD

LP is 11″ SUPPLY -> 10″ AT MANIFOLD

A complete gas tightness check must be performed on all gas-carrying components.

BEFORE TESTING

• Do not smoke while leak testing.

• Never leak test with an open flame.

• Make a soap solution of one part liquid detergent and one part water for leak testing purposes.

• Apply the solution to the gas fittings by using a spray bottle or a brush.

• For LP units, always check with a full LP cylinder.

TO TEST

• Make sure all control valves are in the “OFF” position.

• Apply the soap solution described above to all fittings, hoses, etc.

• Turn the gas supply on.

• CHECK ALL CONNECTIONS! Check from the supply line or LP cylinder up to and including the manifold pipe assembly. Check all the hoses from end to end. Apply the soapy solution liberally to detect any leaks.

• Soap bubbles will appear where a leak is present. If a leak is present, immediately turn off gas supply, tighten any leaking fittings, turn the gas supply back on, and recheck.

• If you cannot stop a gas leak, turn off the gas supply and call the dealer where you purchased your power burner.

• DO NOT USE THE POWER BURNER UNTIL ALL CONNECTIONS HAVE BEEN CHECKED AND DO NOT LEAK.

It will be necessary to adjust the air shutter on the octagonal burner and make fine adjustments to the center burner.

Octagonal Burner Air Shutter Adjustment:

This step is very important to ensure successful burner performance. First, loosen the shutter screw.

• Turn the valve on “HIGH”, match light the burner and allow it to warm up for 10 minutes. Be careful as the burner will be hot.

• If the flame is yellow (insufficient air), turn the air shutter clockwise to allow more air to the burner.

• If the flame is noisy and tends to lift away from the burner ports (too much air), turn the air shutter counter-clockwise to reduce the amount of air.

• Once you have established a good flame, shut off the burner and allow it to cool completely.

• Reach inside the unit and re-tighten the shutter screw.

• Perform one last check that the octagon burner is properly seated on its orifice and rear hanger bracket.

The center burner is similar to many residential gas cooktops. There is an adjustment of the low setting on the valve itself. Consult the appliance manual for instructions.

1. You may now re-install the LED light bar, light switch wires, control panel, knobs, etc. Connect to power and check that the ignition system and lights are working correctly.

2. A conversion label must be attached to the unit next to the existing rating label, located under the drip pan.

3. The qualified service technician must fill in the Gas Type, Manifold Pressure, and BTU Rates for each burner type (per the chart on page 9 of the manual). The technician should sign and date the label as well.