Mobile Range Setup Guide: BTU Per Burner, Propane Sizing, NFPA 96, and Atosa AGR/ACHP/ATSP Specs

The cooking range is the engine of a mobile kitchen. Spec the burners too low and pans stew instead of sear; spec them too high and propane consumption outruns your tank. This guide covers the technical decisions that drive a working hot line: BTU per burner, propane consumption per hour, NFPA 96 clearance, LP vs NG orifice differences, the Atosa AGR/ACHP/ATSP series specs, vibration-resistant gas connections, and the daily leak-test routine that keeps your fire-marshal sign-off intact.

BTU Per Burner: The 25,000-32,000 Sweet Spot

Heat output per burner decides recovery time. Drop a cold pan onto a 15,000 BTU residential burner and the heat dumps into the metal — the next sear is lukewarm, the next is cold. Commercial burners run 25,000-32,000 BTU per burner, the range that holds temperature when a wet pan, frozen protein, or large stockpot lands on the grate.

Burner Output	Best Fit	Recovery Behavior
15,000-20,000 BTU (residential)	Not legal in commercial mobile units	Pans stew on contact, slow recovery
25,000 BTU (entry commercial)	Sauté, boil, simmer on a low-volume menu	Adequate, modest drop-off under load
32,000 BTU (standard commercial)	Most truck applications, including high-volume	Strong sear, fast recovery, propane-balanced
40,000+ BTU (high-output / wok)	Wok cooking, Asian concepts, intense stir-fry	Heaviest fuel draw, requires sized regulator

For a 4-burner range running all four at 32,000 BTU, total top-of-range output is roughly 128,000 BTU per hour. Add an oven base (typically 30,000-35,000 BTU) and the unit pulls 158,000-163,000 BTU at full load. That's the number that determines tank size and refill schedule.

Propane Consumption Per Hour

One pound of propane delivers roughly 21,500 BTU of energy. A 32,000 BTU burner running at full output consumes about 1.5 lb of propane per hour. Working it out for typical setups:

Configuration	Total BTU at Full Load	Propane Burn Rate	20-lb Tank Runtime
2-burner hot plate (ACHP-2)	64,000 BTU	~3 lb/hr	6.5 hours
4-burner range (AGR-4B)	~158,000 BTU	~7.3 lb/hr	2.7 hours
6-burner range (AGR-6B)	~225,000 BTU	~10.5 lb/hr	1.9 hours
Stock pot stove (ATSP, single ring)	80,000 BTU	~3.7 lb/hr	5.4 hours
Stock pot stove (ATSP, dual ring full)	160,000 BTU	~7.4 lb/hr	2.7 hours

Real-world burn rate is lower because not every burner runs at full output the entire service. A 4-burner range averaging 50% load over a 4-hour service consumes roughly 14-15 lb of propane — most operators size at least one 30-lb tank per range plus a backup, swapped between services.

Atosa AGR Series: Full Range with Oven

The Atosa AGR series is the standard for trucks that need an oven base — roasting meats, finishing dishes, holding sides at temp, or baking pizzas. Each top burner is rated 32,000 BTU and the oven base adds 30,000-35,000 BTU.

Model	Burners	Top BTU	Oven BTU	Width	Oven Pan Fit
Atosa AGR-4B	4	128,000	32,000	24"	20" oven — half sheet pan
Atosa AGR-6B	6	192,000	32,000	36"	26.5" oven — full 18×26 sheet pan
Atosa AGR-6B24GR (combo)	6 + 24" griddle	192,000 + 60,000 griddle	32,000	60"	26.5" oven — full sheet pan
Atosa AGR-10B (high volume)	10	320,000	32,000 × 2	60"	Two independent ovens, full sheet pans

Oven temperature range is 175°F to 550°F with a porcelain-enamel interior and 100% safety shutoff pilot. The oven floor on the 36" and larger units fits 18×26 full sheet pans — the 24" AGR-4B is sized for half-pans, which is fine for most trucks but worth knowing before you buy.

Cast iron grates are removable for cleaning, the body is welded 304 stainless, and combo models like the AGR-6B24GR are a workaround for trucks that need a griddle but don't have linear hood space for a separate griddle unit — the 24" polished steel griddle sits next to the open burners under the same hood footprint. Browse current models in the commercial gas range collection or the propane gas range collection if you're sourcing for a mobile build.

Atosa ACHP Series: Countertop Hot Plates

If your menu doesn't need an oven, don't pay for one. A countertop hot plate frees the floor space underneath for a refrigerated chef base, undercounter cooler, or storage. Same 32,000 BTU per burner, no oven, half the height.

Model	Burners	Total BTU	Width	Depth
Atosa ACHP-2	2	64,000	12"	27"
Atosa ACHP-4	4	128,000	24"	27"
Atosa ACHP-6	6	192,000	36"	27"

Three common deployments for the ACHP series in tight kitchens:

• ACHP-2 as a side-burner station — 12" wide, dedicated to sauces, eggs, or one-off sautés next to a flat-top or fryer line
• ACHP-4 stacked on an undercounter cooler — the classic mobile move, same vertical column does prep, cold storage, and active cooking
• ACHP-6 as the primary cookline for high-volume catering rigs and small restaurants without floor space for an AGR-6B

The 12×12 cast-iron grate sections lift off for cleaning, and the full-width crumb tray slides out without disassembly. See current units in the hot plate collection.

Atosa ATSP Series: Stock Pot Stoves for Bulk Prep

A standard range burner is the wrong tool for 20 gallons of birria broth or 15 gallons of tomato sauce. Stock pot stoves sit lower (so you're not lifting a 60-lb pot off a 15" grate at chest height), have a wider grate spread for the pot diameter, and use multi-ring burners that deliver heat across the full pot bottom.

• Single-ring ATSP units — 80,000 BTU on one burner ring, suitable for 20-30 quart stockpots and most truck broth volumes
• Dual-ring ATSP units — inner + outer ring, up to 160,000 BTU when both rings are firing, for 40+ quart pots and faster boil-ups

The cost-saving rationale: a stock pot stove keeps your main range burners free during 4-hour broth simmers. Without it, one of your 32,000 BTU range burners is tied up holding a low simmer when it should be searing tickets. Browse models in the stock pot stove collection.

NFPA 96: Clearance to Combustibles

Open-flame cooking equipment requires clearance to anything combustible — wall framing, insulation behind a stainless skin, plywood substrate, or adjacent equipment surfaces. The standard NFPA 96 minimums:

• Sides and back of a gas range — minimum 6 inches to combustible surfaces. Stainless wall skin alone doesn't qualify if there's wood or insulation behind it.
• Range to fryer — minimum 18 inches separation, or a steel splash guard between them, because oil drift from the fryer is a flame fuel
• Range to refrigeration — minimum 6 inches if the cooler has a side condenser; more if condenser draws from the side facing the range
• Filter to cooking surface — minimum 18 inches above the highest cooking surface (24 inches for charbroilers and high-output equipment)

Failing clearance doesn't only risk a fire — it fails fire-marshal inspection and delays your operating permit. Local jurisdictions sometimes require more than the NFPA minimum; confirm with the inspector before final mounting.

LP Conversion: Why It's Not a DIY Job

Almost every commercial range ships configured for natural gas (NG). On a truck running propane (LP), the orifices and regulator have to be swapped. The orifice is a precision-drilled brass insert that meters fuel flow — propane is denser and burns hotter per cubic foot than natural gas, so LP orifices have a smaller hole.

Symptoms of a botched conversion:

• Yellow tipping — the flame is yellow at the tip instead of pure blue. Soots up the bottom of pans. Indicates incomplete combustion (too much fuel for the air mix).
• Carbon monoxide production — the more dangerous version of the same problem. CO is colorless and odorless; in an enclosed truck it builds fast.
• Roaring or lifting flame — too much fuel pressure, often from a regulator set for NG (3.5" W.C.) instead of LP (10" W.C. manifold pressure).

Most Atosa units include the LP conversion kit in the box. The kit has to be installed by a certified gas technician — not because the parts are exotic, but because the regulator pressure adjustment requires a manometer and the leak test has to be done with calibrated soap solution at every joint touched during the swap.

Manifold Pressure Reference

Fuel	Standard Manifold Pressure
Natural Gas (NG)	3.5" Water Column
Liquid Propane (LP)	10" Water Column

Gas Line Sizing and Vibration

Mobile vibration is the silent killer of gas connections. Every pothole loosens fittings; every speed bump flexes a hose at the connector. Build the gas system to survive that environment.

• Use braided stainless flex hose for the final connection between manifold and appliance. Black iron pipe inside a moving truck cracks at threaded joints.
• Quick-disconnect fittings let you decouple equipment for cleaning without breaking thread sealant. Each disconnect cycle gives a fresh, leak-tight connection.
• Restraining cable — required by code on flex-hose installs so the appliance can't roll or shift far enough to snap the line. Cable attaches the unit to the wall or floor anchor.
• Sized supply line — a 4-burner range plus an oven needs 1/2" supply minimum. A 6-burner unit on a single regulator usually needs 3/4". Undersized line causes pressure drop at the manifold; you'll see weak flame even with a full tank.
• Two-stage regulator — the first stage drops tank pressure (100+ PSI) to 10 PSI; the second drops 10 PSI to 11" W.C. for appliances. Single-stage regulators on multi-appliance trucks fluctuate as load changes.

Daily Leak Test Routine

Vibration, temperature swings, and time all loosen connections. The soapy-water test takes 5 minutes and prevents the worst-case scenario.

1. Open the propane tank valve fully
2. Mix 1 part dish soap to 4 parts water in a spray bottle
3. Spray every joint from the tank outlet to the appliance connector — regulator outlet, every union, every flex-hose end, the appliance shutoff valve
4. Watch for bubbles. A growing bubble cluster = active leak. A single static bubble from spray = nothing
5. If you find a leak: shut off the tank valve immediately, ventilate, and either tighten the fitting and re-test, or replace the suspect part

Run this check before service every morning. Run a full check at every fitting that was touched, moved, or disconnected. Replace flex hoses every 3-5 years regardless of how they look — UV, grease, and ozone degrade the rubber even when no cracks are visible.

Pilot, Thermocouple, and Common Failures

Pilot Light Won't Stay Lit

A standing pilot heats a thermocouple, which generates a tiny voltage that holds the gas valve open. When the pilot drops, the valve closes. Three causes from most to least common:

• Drafts — air pulled up through floor vents or down through the hood blows out the flame. Shield the pilot or shift the unit 6" to break the airflow path
• Failed thermocouple — voltage drops over time. Replacement is $15-30 in parts, 10 minutes of work
• Clogged pilot orifice — debris in the pilot tube blocks fuel. Clean carefully with a thin wire (not a toothpick — broken wood inside is worse than the original clog)

Yellow or Sooty Flame

A clean flame is blue with a small yellow tip. Mostly yellow flame means too much fuel for the air mix. Causes:

• Clogged burner ports — grease and food debris block port holes. Clean with a stiff wire brush or specialized port-cleaning tool
• Air shutter misadjusted — the metal collar at the burner-tube base controls air intake. Open it slightly until flame turns blue
• Wrong orifice for fuel type — running NG fuel through LP orifices, or vice versa, always produces yellow tipping. Stop and call a gas tech

Compliance Checklist Before First Service

1. Range professionally converted to LP and pressure-tested at 10" W.C. manifold
2. Two-stage regulator installed and verified at output pressure
3. Propane tank cage-mounted outside cooking compartment with adequate ventilation
4. Restraining cable installed on every flex hose
5. NFPA 96 clearances verified (6" sides/back, 18" range-to-fryer, 18-24" filter-to-surface)
6. Type I hood with welded ductwork sloped back to hood
7. Wet-chemical fire suppression installed and tagged (covers any open-flame surface)
8. K-class fire extinguisher mounted within reach
9. Daily leak-test soap solution on the truck
10. LP gas detector installed and battery-tested
11. Fire-marshal sign-off completed
12. Health-department sign-off on cooking layout

Layout: Where the Range Goes

The range belongs on the same wall as the rest of the cookline, with prep upstream and dump/service downstream. Crisscrossing paths between line cooks and the order window are where rush-hour collisions happen.

• Range adjacent to fryer is fine with 18" separation or a steel splash guard between them
• Refrigeration on the range side is fine with 6" clearance if the cooler has a side condenser. See the food truck refrigerator guide for placement.
• Aim hot exhaust away from the service window and away from any reach-in compressor
• Leave clear access behind the range for monthly oil and grease cleanout
• Mount the range with adjustable feet bolted through the chassis floor, not just resting on top of it

Cost Ranges by Type

Type	Typical Range
Atosa ACHP-2 (2-burner hot plate)	$300 – $800
Atosa ACHP-4 (4-burner hot plate)	$600 – $1,400
Atosa ACHP-6 (6-burner hot plate)	$900 – $1,800
Atosa AGR-4B (4-burner range with oven)	$1,200 – $2,500
Atosa AGR-6B (6-burner range with oven)	$1,800 – $3,500
Atosa ATSP single-ring stock pot stove	$300 – $700
Atosa ATSP dual-ring stock pot stove	$500 – $1,200

Financing helps when buying outright would eat startup capital — restaurant equipment financing spreads the cost into monthly payments. Browse current models in the commercial gas range collection, the hot plate collection, or the stock pot stove collection.

Where the Range Fits in the Larger Build

The range is one of nine systems on a mobile build — generator, refrigeration, cookline, ventilation, water, propane, electrical panel, commissary, and chassis. For the full build sequence and how each system depends on the others, start at the food truck equipment guide. For ventilation specifics that pair with an open-flame range, see the related fryer setup notes in the food truck fryer setup guide.

Frequently Asked Questions

How many BTUs per burner does a commercial range need?

25,000-32,000 BTU per burner is the commercial standard. 32,000 BTU is the sweet spot for most truck applications because it delivers fast pan recovery without outrunning typical propane supply. Wok cooking and high-volume Asian concepts may require 40,000+ BTU per burner, which means a sized supply line and a higher-capacity regulator.

How much propane does a 4-burner range consume per hour?

A 4-burner range at 32,000 BTU per burner running all four burners at full output consumes roughly 7.3 lb of propane per hour. Add an oven base (30,000-35,000 BTU) and full-load consumption rises to about 9 lb per hour. Real-world average is closer to 50% load, so a 4-hour service typically burns 14-15 lb of propane.

What is NFPA 96 clearance for a gas range?

NFPA 96 requires minimum 6-inch clearance from the sides and back of a gas range to any combustible surface — wood framing, insulation, plywood — even if covered by stainless skin. Range-to-fryer minimum separation is 18 inches or a steel splash guard between them. Filter-to-cooking-surface clearance is 18-24 inches above the highest grate.

Can I convert a natural gas range to propane myself?

No, even if the conversion kit is in the box. The orifices have to be swapped, the regulator pressure has to be re-set with a manometer to 10" Water Column for LP, and every joint touched during the swap has to be leak-tested with calibrated soap solution. A botched conversion produces yellow tipping, soot on pans, and dangerous carbon monoxide. Use a certified gas technician.

What is the difference between manifold pressure for LP and natural gas?

Natural gas runs at 3.5" Water Column manifold pressure. Liquid Propane runs at 10" Water Column. They are not interchangeable — LP through an NG-pressured regulator burns lean and dirty; NG through an LP-pressured regulator roars and lifts off the burner. The regulator and the orifices both have to match the fuel type.

What gas line size do I need for a 4-burner range plus oven?

1/2" supply line minimum. Six-burner units on a single regulator usually require 3/4". Undersized line causes pressure drop at the manifold, which shows up as weak flame and slow recovery even when the propane tank is full. Have all gas lines installed and pressure-tested by a licensed propane technician.

Why does my pilot light keep going out?

Three common causes. First, drafts from floor vents or hood airflow blow out a standing pilot — shield it or shift the unit 6 inches. Second, a weakening thermocouple no longer holds the gas valve open; replacement is $15-30 in parts. Third, a clogged pilot orifice from grease or debris — clean carefully with thin wire, never a toothpick.

What does a yellow flame on a burner mean?

Yellow flame indicates incomplete combustion. Causes are clogged burner ports (grease blocking holes), air shutter set too lean (not enough air mixing with fuel), or wrong orifice for fuel type. Clean ports first, adjust air shutter second, and if those don't fix it, stop service and call a gas tech — wrong-orifice combustion produces carbon monoxide.

How often should I leak-test gas connections?

Daily, before service. Soap-and-water spray at every joint from tank to regulator to manifold to appliance. Monthly full-system test on every fitting. Replace flex hoses every 3-5 years regardless of visual condition — UV, grease, and ozone degrade rubber even when no cracks are visible.

Do I need a hood over a stock pot stove?

Yes. Any gas-fired equipment producing heat or steam needs to be under a Type I (grease-rated) ventilation hood. Stock pot stoves don't produce as much grease vapor as fryers, but the steam, BTU output, and combustion gases require the same exhaust setup as a regular range.