THERMA-TEK RANGE CORPORATION QUALITY AND STRENGTH GAS RESTAURANT RANGE PARTS / SERVICE MANUAL Models covered in this manual include: TMDS24-4-1 (4 Open Top Burners, 1 Space Saver Oven) TMDS36-6-1 (6 O T Burners, 1 Standard Oven) TMDS48-8-2 (8 O T Burners, 2 Space Saver Ovens) TMDS60-10-2 (10 O T Burners, 2 Standard Ovens) TMDS60-6-24RGB-2 (6 O T Burners, Raised Grid/Broil, 2 Ovens) TMDS72-12-2 (12 O T Burners, 2 Standard Ovens) And models utilizing available options including: Manual & Thermostatic Griddles, Hot Tops, Radiant & Char- Rock Broilers, Range Base Convection Ovens, and Storage Cabinet Bases.
INTRODUCTION The Gas Restaurant Range Parts / Service manual contains Installation & Operation Recommendations. It also includes Troubleshooting and Technical Data such as Orifice Hood Sizing and Gas Pressure Requirements. The material presented should be used in conjunction with the Owners Manual, Professional Training, Service Experience, and Industry Standard Practices. TABLE OF CONTENTS: PAGE Model Number Identification..3 Gas Restaurant Range Standard Features 3 Gas Restaurant Range Standard Features (continued)....4 Rating Plate Location..5 Identifying the Age of Equipment by Warranty Number 5 Gas Specifications..6 Lighting Standing Pilots.7 Shut Down -Nightly and Complete 8 Open Top Burner Air Adjustment.. 8 Setting the Bypass Flame on Thermostatic Griddles..9 Calibration Check and Thermostat Recalibration...9 Oven Pilot Safety System..10 Trouble Shooting the Pilot Burner.10 Control Tips Thermocouple / Safety 11-14 Parts Exploded View and Detail List...15-26 Notes.27 2
Model Number Identification EXAMPLE: TMDS60-10-2N T (Therma) M (Medium) D (Duty) S (Standard Aluminized Oven) 24, 36, 48, 60, 72 (The Width of the Unit) -4, -6, -8, -10, -12 (The Number of Open Burners) Optional -HT (Hot Top), - G (Manual Griddle), - TG (Thermostatic Griddle), GP (Grooved Plate), - RB (Radiant Broiler), - CRB (Char-Rock Broiler), - 0 (Storage Cabinet Base), - C (Range Base Convection Oven) The Final Character N or L (NATURAL or LP Gas). Gas Restaurant Range Standard Features Gas Restaurant Ranges consist of a welded frame construction. Fully stainless steel exterior. 6 (152.5 mm) adjustable legs. Gas pressure regulator provided. One year limited parts and labor warranty. Open Top Burners Cast iron lift off burner heads for easy cleaning. Rated at 30,000 BTU s (8.79 kw). Top grate supports located every 12 assuring structural integrity. Spill-proof pilot ignition system. Individual 12 (305 mm) x 12 (305 mm) cast iron top grates. Burner is controlled by a brass valve with infinite adjustment. 3
Griddles 5/8 thick, highly polished steel plate. Spatula width grease trough. One heavy-duty, steel tube burner per 12 section; at 20,000 BTU/hr. Each 12 section is controlled by a valve. Each 24 section is controlled by a thermostat. Manual valve control is standard. Thermostat control is available. Large capacity grease container. Radiant Broilers One heavy-duty cast-iron H-Type burner per 12 section; 30,000 BTU/hr. Heavy cast-iron radiant with multiple heat sinks - (2) per burner. Heavy-duty cast-iron cooking grates. Single piece precision brass valves with infinite heat control. Easy to remove drip pans Char-Rock Broilers One heavy-duty cast-iron H-Type burner per 12 section; 30,000 BTU/hr. High quality lava rocks on cast iron supports provide maximum heat. Burners protected by heat shield to prevent blockage of ports and pilot. Heavy-duty cast-iron cooking grates. Single piece precision brass valves with infinite heat control. Easy to remove drip pans. Range Base Convection Oven 1/3 Hp convection oven motor Three oven racks Three rack guide positions 6 Ft. - 120 volt cord and plug. 4
RATING PLATE LOCATION The Rating Plate (sticker) on all Gas Restaurant Range Models is located on the backside of the lower front panel. It flips down to expose the Rating Plate and Operating Instructions. On double oven models, the Rating Plate is behind the lower front panel of the right oven. WARRANTY SERIAL NUMBER THERMA-TEK SERIAL NUMBER & DATE CODE Date of manufacture is a date code and is part of the serial number. (a) (c) Example: 09J00001A (b) (d) (a) Year Code: Use the last two digits of the year. 07 = 2007 08 = 2008 09 = 2009 (b) Month Code: A=Jan, B=Feb, C=Mar, D=Apr, E=May, F=Jun, G=Jul, H=Aug, I=Sep J=Oct, K=Nov, L=Dec (c) 5 Digit Serial Number: This number is reset to zero on the new year. (d) Engineering Digit: A is used for new release. Anytime a design element is changed that would affect service, this digit would be changed to B. Each time a change is made, the letter is changed going down through the alphabet. 5
RESTAURANT RANGE GAS SPECIFICATIONS BURNER TYPE BTU / kw NAT Hood Orifice # PRO Hood Orifice # Open Top 30,000 / 8.79 40 53 Griddle 20,000 / 5.86 48 55 Raised Griddle / Broiler 15.000 / 4.39 51 57 Hot Top 20,000 / 5.86 48 55 Char-Rock Broiler 30,000 / 8.79 39 52 Radiant Broiler 30,000 / 8.79 39 52 Standard Oven 35,000 / 10.25 36 51 Convection Oven Base 35,000 / 10.25 37 52 Space Saver Oven 27,000 / 7.9 42 53 PRESSURE REGULATOR A Pressure Regulator is provided with every Gas Restaurant Range and must be installed prior to start up. GAS PRESSURE Natural Liquefied Propane MANIFOLD SIZE 5.0 Water Column / 12.45 mbar 10.0 Water Column / 24.90 mbar ¾ N.P.T. on all Restaurant Ranges. LOCATION Gas manifold inlet is left facing, inboard 113/16. 6
SHUTDOWN Nightly shutdown: Turn burner valves or thermostats to off position. Pilots will remain lit. Complete shutdown: Turn burner valves or thermostats to off position. Turn main gas supply to range off. 8
OVEN / GRIDDLE THERMOSTAT OPERATION When An Oven or Griddle reaches the temperature at which the dial was set, the control cuts down the flow of gas to the amount required to maintain that temperature. This minimum burner flame is called the bypass flame. The control must provide enough bypass gas to keep the entire burner lighted. If not, the bypass must be set carefully and accurately as follows: Setting the Bypass Flame 1. With the pilot lighted, turn the thermostat dial to Full On. 2. After 5 minutes, turn the dial clockwise to the point slightly beyond the first mark on the dial. 3. Carefully remove the dial. 4. With a straight-bladed screw driver, turn the bypass adjustment screw counter-clockwise to increase the flame, clockwise to decrease the flame, until there is a minimum flame (approximately 1/8 high) on the entire burner. This flame should be stable without lifting. With a good bypass established, we can check the thermostat s calibration. An accurate pyrometer or other reliable test instrument is required. Checking Calibration 1. Set the thermostat dial to 400 F mark. That s 240 C. 2. To allow the temperature to stabilize, the control must cycle at least three times (min. 15 minutes) before taking a meter reading. 3. Continue to check temperature at 5 minute intervals until two successive readings are within 5 degrees of each other. If readings are not within 20 degrees of the dial setting, calibration is required. Calibrating the Control 1. With the dial insert removed, hold the dial firmly. 2. With a straight bladed screwdriver, push and hold the calibration screw located down the center of the stem. Do not turn the screw. 3. While holding the calibration screw firmly, turn the dial to the set point matching the actual temperature shown on your test instrument. Remove the screwdriver. Replace the dial insert. 4. Set the temperature at 400 (240 C). After 15 minutes, check temperature. It should be within 20 degrees of the dial setting. 5. A control exhibiting 50 or more degrees out should be replaced. 9
PILOT SAFETY & THERMOCOUPLE OPERATION Therma-Tek has utilized several manufactures of safety valves and thermocouples. The following includes both general and Robertshaw specific instructions. Heating the thermocouple tip by the pilot flame produces an electrical potential that energizes the safety s magnet that holds the main and pilot valves open. When the pilot is out or improperly adjusted, insufficient heat is applied to the thermocouple tip. Therefore, inadequate electrical generation results in the control shutting off. 10
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PART NUMBER DESCRIPTION RESTAURANT SERIES RANGE
ITEM NUMBER PART NUMBER DESCRIPTION RESTAURANT SERIES RANGE 1 81022-40 Open Top Orifice Hood # 40 (NAT) 81022-53 Open Top Orifice Hood # 53 (lp) 2 81003-01 1/8 NPT Pipe Plug 3 81018 Pilot Adjust Valve Open Top 4 80030 Manual Gas Valve Brass Elbow 90 3/8CC x 1/4 NPT (Oven Thermostat Fitting) 5 81015 6 80019 Tee Thermostat 7 80014 BJ Bezel Assy (Oven) 8 80015-02 BJ Oven Knob 9 80017-02 BJWA Oven Thermostat 10 30273 Oven Bulb Clamp 11 87008 Bulb Clip 12 30102 Burner Rest 13 30473 Open Top Pilot Tube WA 14 80029-01 Air Shutter 15 82002 Front Venturi 16 82306 Top Grate Commercial 17 82000 Burner Head 18 82001 Rear Venturi 19 30102 Top Grate Support 20 90002 Pilot Tubing Assy 21 80026-01 Regulator 5" NAT 80026-02 Regulator 10" LP 22 30266-01 36" SDHS Rear Panel 30266-02 60" SDHS Rear Panel 30266-03 24" SDHS Rear Panel 30266-04 48" SDHS Rear Panel 30266-05 72" SDHS Rear Panel 23 30281-01 36" SDHS Shelf WA 30281-02 24" SDHS Shelf WA 30281-03 48" SDHS Shelf WA 30281-04 60" SDHS Shelf WA 30281-05 72" SDHS Shelf WA 24 30270-01 36" SDHS Front Panel 30270-03 48" SDHS Front Panel 30270-04 60" SDHS Front Panel 30270-06 60" RGB SDHS Front Panel 30270-07 24" SDHS Front Panel 30270-08 72" SDHS Front Panel 25 30110-01 36" Drip Pan Handle 30110-02 Drip Pan Handle (TMD36-24G-2-1) 30110-03 Center Drip Pan Handle 60" 30110-04 Drip Pan Handle 60" 30110-05 RGB Drip Pan Handle 30110-06 RGB Center Drip Pan Handle 60"
30110-07 Drip Can Handle 24" RGB 30110-08 Drip Pan Handle 24" 26 30111-01 36" Drip Pan 30111-02 Drip Pan (TMD36-24G-2-1) 30111-03 Drip Pan 60" 30111-04 Center Drip Pan 60" 30111-05 RGB Drip Pan 30111-06 RGB Center Drip Pan 60" 30111-07 36" CRB/RB Drip Pan 30111-08 24" Drip Pan 30111-09 24" CRB/RB Drip Pan 30111-10 12" Broiler Drip Pan 30111-11 Center 60" Drip Pan (TMD60-4-36CRB) 30111-12 60" Drip Pan (TMD60-4-36CRB) 27 80021-02 Oven Pilot (NAT) 80021-01 Oven Pilot (LP) 28 82022 Straight Tube Burner 29 30436 Straight Tube Burner Bracket 30 80002 Oven Rack Side 31 80001 Commercial Oven Rack 30" Oven 80045 Commercial Oven Rack 24" Oven 32 30086 Oven Rack Clip Assy 33 30107 Lower Front Panel 30" 30107-01 Lower Front Panel 24" 34 30094 Front Air Shield 36" 30094-01 Front Air Shield 24" 35 80031 Piezzo Igniter 36 30129 Piezzo Igniter Bracket 37 90007 Oven Pilot Tubing 38 80018 TS11 Safety Valve 39 30126 TS11 Safety Valve Bracket 40 81022-33 Oven Orifice Nat #33 81022-51 Oven Orifice LP #51 81022-42 Space Saver Oven Orifice Nat #42 81022-53 Space Saver Oven Orifice LP #53 81022-37 Range Base Oven Orifice Nat #37 81022-52 Range Base Oven Orifice LP #52 41 30087 Lower Front Panel Bracket WA 42 30108-01 Corner Column LH 36" WA 43 30108-02 Corner Column RH 36" WA 44 80012 6" Leg 45 80025-01 6" Swivel Caster 46 80025-02 6" Swivel Caster W/Brake 47 30015 Door Liner 30" WA
48 30117-01 Door Frame Assembly 30" 30117-02 Door Frame Assembly 24" 49 80016 Door Spring 50 30130-05 Oven Door Insulation 30" 30130-08 Oven Door Insulation 24" 51 87006 Pal Nut 52 82009 Logo Therma-Tek Range Corp 53 30116 Door Handle Stiffener Bracket 30" 30116-01 Door Handle Stiffener Bracket 24" 54 30016 Door Panel 30" 30016-01 Door Panel 24" 55 30231-01 Door Handle 30" 30231-02 Door Handle 24" 56 82004 Door Handle End 57 30012 Oven Flame Spreader 58 30010-01 Oven Bottom 30" WA-PC 59 80000 Plastic Knob 60 30103-01 Front Rail 12" WA 30103-02 Front Rail 24" WA 30103-03 Front Rail 36" WA 30103-04 Front Rail 48" WA 30103-05 Front Rail 60" WA 30103-06 Front Rail 72" WA 30103-07 Front Rail 30" WA 61 30106-01 Front Panel 36" 30106-02 Front Panel 60" 30106-03 Front Panel 36" TMD36-24-2-1 30106-04 Front Panel 36" TMD36-36G-1 30106-05 Front Panel 60" RGBa 30106-06 Front Panel 60" TMD60-24G-6-2 30106-08 Front Panel 60" TMD60-36G-4-2 30106-09 Front Panel 60" TMD60-4-36G-2 30106-10 Front Panel 24" 30106-11 Front Panel 36" TMD36-24G-2-1 30106-12 Front Panel 48" TMD48-24G-4-2 30106-13 Front Panel 48" 30106-14 Front Panel 24" TMD24-12G-2-1 30106-15 Front Panel 24" TMD24-2-12G-1 30106-16 Front Panel 24" TMD24-24G-1 30106-17 Front Panel 36" TMD36-4-12G-1 30106-18 Front Panel 72" 30106-19 Front Panel 36" TMD36-2-24G-1 30106-20 Front Panel 48" TMD48-48G-2 30106-21 Front Panel 72" TMD72-36G-6-2 30106-22 Front Panel 72" TMD72-48G-4-2
30106-23 Front Panel 60" TMD60-60G-2 30106-24 Front Panel 48" TMD48-2-36G-2 30106-25 Front Panel 48" TMD48-36G-2-2 30106-26 Front Panel 48" TMD48-24G-4-2 30106-27 Front Panel 60" TMD60-10-1-1C 30106-28 Front Panel 60" TMD60-10-1C-1 30106-29 Front Panel 48" TMD48-12G-6 30106-30 Front Panel 60" TMD60-12G-8-2 30106-31 Front Panel 72" TMD72-6-36G-2 30106-32 Front Panel 72" TMD72-4-48G-2 30106-33 Front Panel 48" TMD48-4-24G-2 30106-34 Front Panel 72" TMD72-24G-8-2 30106-35 Front Panel 72" TMD72-72G-2 30106-36 Front Panel 48" TMD48-6-12G-2 30106-42 Front Panel 36" RBCO-TSTAT-Right 30106-43 Front Panel 36" RBCO-TSTAT-Left 30106-44 Front Panel 60" TMD60-10-2C 30106-45 Front Panel 72" RBCO 30106-46 Front Panel 48" TMD48-8-1CO-O 30106-47 Front Panel 60" TMD60-48G-2-2 30106-48 Front Panel 36" TMD36-2-12G-1 30106-49 Front Panel 60" TMD60-6-24G-1C 30106-50 Front Panel 72" TMD72-8-24G-2 30106-51 Front Panel 60" TMD60-8-12G-2 30106-52 Front Panel 60" TMD60-24G-6-1C-1 30106-53 Front Panel 60" TMD60-24G-6-1-1C 30106-54 Front Panel 60" TMD60-6-24G-1C-1 30106-56 Front Panel 60" TMD60-4-36G-1C-1 30106-58 Front Panel 60" TMD60-24G-6-2C 30106-59 Front Panel 60" TMD60-6-24G-2C 30106-60 Front Panel 60" TMD60-6-24G-1-1C 30106-61 Front Panel 60" TMD60-36TG-4-2C 30106-63 Front Panel 60" TMD60-4-36TG-2C 19
RAISED GRIDDLE BROILER (RESTAURANT SERIES RANGE) 1 82307-02 Griddle Plate 24" 2 30382 RGB Drain Extension WA 3 30110-05 RGB Drip Pan Handle 4 30111-05 RGB Drip Pan 5 81016-02 Orifice Elbow 3/8-27 x 1/4 npt 6 81022-51 Orifice #51 NAT 81022-57 Orifice #57 LP 7 81014 Elbow 3/8cc x 3/8-27F
8 30299 RGB Orifice Bracket 9 30302 RGB Front Shield 10 90002 Pilot Tubing Assy 11 82022 Straight Tube Burner 12 30229 RGB Radiant 13 30294-03 RGB Grease Can Lid 14 30406-01 RGB Grease Can Assy 15 80004 BG Rack 16 80000 Commercial Knob 17 80030 Manual Gas Valve 18 81018 Pilot Adjustment Valve 19 90013 Flexible Gas Tubing 3/8 x 8 20 30298-01 RGB Drip Shield WA 21
GRIDDLE 22
GRIDDLE (RESTAURANT SERIES RANGE) 1 30215-01 Griddle WA 12" 30215-02 Griddle WA 24" 30215-03 Griddle WA 36" 30215-04 Griddle WA 48" 30215-05 Griddle WA 60" 30215-06 Griddle WA 72" 2 30226-01 Drain Extension WA-Range 3 30406 Grease Can Assy 30406-02 12" Grease Can Assy 4 30294-02 Griddle Grease Can Lid 5 80015-01 Griddle Thermostat Knob 6 80014 Bezel 7 80017-01 GriddleThermostat 8 80019 Thermostat Tee 9 81015 90 Elbow 3/8cc x 1/4 NPT 10 81027 Tee 3/8 cc x 1/4 NPT 11 90013 Flexible Gas Tubing 3/8 x 8 12 80030 Manual Gas Valve 13 81018 Pilot Adjustment Valve 14 81003-01 1/8 NPT Pipe Plug 15 81014 Elbow 3/8cc x 3/8-27 F 16 81016-01 Orifice Elbow 3/8cc x 3/4-16 17 81022-48 Orifice #48 NAT 81022-55 Orifice #55 LP 18 80029-02 Air Shutter- H Burner 19 82022 Straight Tube Burner 20 30522 Griddle Burner WA (Bullet) 21 90038 Pilot Tip Assy 23
BROILERS: RADIANT & CHAR ROCK(RESTAURANT SERIES RANGE) 1 89015 Lava Rocks
2 82008 Waffle Grate 3 30254 Waffle Grate Support 4 30255 Radiant Support Bracket 5 82007 Broiler Radiant 6 82011 Broiler Grate 7 30242 Heat Shield: CRB 8 30242-01 12" Heat Shield: CRB 9 30242-02 Heat Shield:RB 10 30522 Griddle Burner WA (H Burner) 11 30391-01 Broiler Top WA 12" 30391-02 Broiler Top 24" 30391-03 Broiler Top 36" 12 30226-01 Drain Extension WA-Range 13 30243 Orifice Bracket 14 81003-01 1/8 NPT Pipe Plug 15 81014 Elbow 3/8cc x 3/8-27 F 16 81016-01 Orifice Elbow 3/8cc x 3/4-16 17 90013 Flexible Gas Tubing 3/8 x 8 18 81022-39 Orifice #39 NAT 81022-52 Orifice #52 LP 19 80000 Commercial Knob 25
RBCO: CONVECTION OVEN(RESTAURANT SERIES RANGE) 1 80064 Indicator Light 2 80063-03 Rocker Switch DPDT-Power 3 80060 Mechanical Thermostat 4 80000-02 Thermostat Knob-Convection Oven 5 80062 Solenoid Valve 6 80075 Door Micro Switch 7 30530 RBCO Motor Assy 8 80084 RBCO Rack 26