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Middleby Marshall PS540 User's Manual

1. 17 GAS RATING us 17 MINIMUM GAS METER RATING 17 MINIMUM GAS PIPE SIZE 17 GAS SAFETY VALVE uns 17 REQUIRED GAS SUPPLY PRESSURE 17 SUGGESTED 17 User supplied Items 17 Il VENTILATION GUIDELINES 18 VENTILATION HOOD 18 VENTILATION CAPTURE TEST 18 Ill ELECTRICAL CONNECTION INFORMATION FOR PS540 SERIES OVENS 5 ere 19 IV ELECTRIC SUPPLY FOR GAS HEATED OVENS 19 V GAS SUPPLY FOR GAS HEATED OVENS 20 VI CONVEYOR REAR STOP AND END STOP INSTALLATION 21 SECTION 3 INSTALLATION CONTROL FUNCTIONS 23 COMPONENT INFORMATION AND LOCATION 24 A Door Safety Switch 24 B Blower Switch a 24 C Switch aana 24 D Temperature Controller 24 E CONVEVOF s ein 25 MEASURING CONVEYOR SPEED 25 Ill STEP BY STEP OPERATION 26 Startup Procedures en 26 TABLE OF CONTENTS Continued Page Daily Stare er
2. 6 21866 2 102 7 15 OgdINOO 12217 NOlLdIHOS3G N d ALO 3NVd 1OHINOO 55 SECTION 6 PARTS LIST 56 SECTION 6 PARTS LIST 91 1 X 2 S LZc0S 81 H3 13lAVIG 8 8 1145 HYTIOO 66646 2 2 ZEE X 91 QI 8 9 1vIO3dS 2100 12022 91 13M MO V8 H LLO UNI 011198 Gl NVI IVIXV 29881 115 001 X 91 8 X 992 OS A3M 0100 1991 51 LAVHS 7909 cl Jan 440 ANVLS 39ldlHO NVA 8010 00698 8 L3 INI 0887 01 TIVM MOVE 88 6 OZ 48 X 46 01 GH M M3HOS 2020002 8 11 9 X 91 8 5 889 GH XH M3HOS 000 92616 2 2 48 8 M9O 18 MOTIId 2 9 SS 8 6 5 13 000 91 1 85 6 dZ 8 6 1901 LI 1dS 000 7 05 ONITIVISNI3H 340439 54 OL Z 5 13 045 1 42145 2100 0111 Ve 155 1 91 8 6 HH 5 626066 5 O0rSSd 1349Vyg 1 99887 2 HZEMV 09406 AHOL AFTINd 49119 NOILdlH2S3G N d ALO NS 5 83MO 18 57 SECTION 6 PARTS LIST SECTION 6 PARTS LIST 0951 dHOS L HOLOIN 26427 86 NVd 90820 00698 2 26 SLO IS
3. 40 1 2 1028 mm 76 1 2 1943 mm 80 2032 mm 58 7 16 1484 mm 76 1930 mm 57 9 16 62 1462 1588 35 13 16 910 39 7 8 1013 17 5 16 440 RESTRAINT CABLE INSTALLATION Install the restraint cable assembly on the oven as shown in Figure 2 6 Cooling Fan Rear Surface of Oven 3 4 19mm 068088688888880066088800000666686060060068000008060 000000800000000000000000000000008800000000000000000 49 3 4 Restraint 1264mm Cable Assembly Restraint 3 4 19mm Cable Eyebolt Assembly Wall of Structure To Eyebolt Rear View On Wall Figure 2 8 Restraint Cable Assembly Installation 16 2 INSTALLATION UTILITY ROUGH IN DIMENSIONS AND POSITIONING FOR PS540 SERIES OVENS WARNING DO NOT USE CONDUIT OR GAS LINE FOR GROUND CONNECTION CAUTION IT IS REQUIRED THAT THE OVEN BE PLACED UNDER A VENTILATION HOOD FOR ADEQUATE AIR SUPPLY AND VENTILATION ELECTRIC AND GAS SUPPLY TO BE PROVIDED BY CUSTOMER ELECTRICAL SAFETY SWITCH 15 Amp circuit breaker fused disconnect switch with lockout tagout electrical shutoff for each oven Wire each oven separately ELECTRICAL SPECIFICATIONS DOMESTIC or EXPORT 208 240V blower motor 1
4. 44 C Ventilati n 44 D Checking the Blower Fan Belt 44 E Blower Fan Shaft Bearing Lubrication 45 Split belt Conveyor Shaft Cleaning 45 IV MAINTENANCE EVERY 6 MONTHS 47 PS540 SERIES GAS OVEN KEY SPARE PARTS KIT PIN 36805 ii 48 KEY SPARE PARTS sisas 48 SECTION 5 TROUBLESHOOTING Troubleshooting Charts 49 SECTION 6 PARTS LIST OVEN PANELS WINDOW AND LEGS 53 CONTROL PANEL 55 BLOWER AND SHROUD 57 CONVEYOR O 59 SPLIT BELT CONVEY OR 61 GAS BURNER PIPING ASSEMBLY 63 MACHINERY COMPARTMENT 65 SECTION 7 ELECTRICAL SCHEMATICS Wiring Diagram G208 240 50 60 3W PS540 67 NOTE Wiring Diagrams are in Section 7 of this Manual The diagram for each oven is also on the lower inner surface of its Control Console SECTION 1 DESCRIPTION SECTION 1 DESCRIPTION MODEL IDENTIFICATION TheMiddleby Marshall P5540 CS 5 gt O Q gt O O 5 O Y Lo x O 9
5. Position 3 Remove the outside master links on the right and left sides of the conveyor belt as shown in Figure 4 29 Figure 4 29 Figure 4 31 41 SECTION 4 Replacing Conveyor Belt 6 Reconnect the inside master links Figure 4 32 If a section of the conveyor belt needs replacing it can be done with the conveyor assembly either in or out of the oven The section of the conveyor belt furnished with the oven in the installation kit may then be used to replace a section Follow the preceding procedure Conveyor belt link removal which outlines the disassembly procedure O J Attaching Drive Chain 1 If drivesprocket assembly was removed reassemble it into the conveyor drive shaft Be sure flat on end of drive shaft aligns with set screw in conveyor shaft collar Once in place tighten 3 32 set screw 2 Lift conveyor and install drive chain to conveyor drive sprocket and motor sprocket D Figure 4 32 NOTE The outside master links have right and left sides to them The right edge master link has an open hook facing you as shownin Figure 4 33 This will match up with the outer edges ofthe conveyor belt Remember this hook 21 TTT TTT Figure 4 35 Figure 4 33 The angle plate located on the underside the con veyor must be against the lower end plug This is true on BN
6. 3 Open the window to allow the oven to cool faster Keys as necessary Oen to adjust the set e N 527 NN point 4 After the oven has cooled and the blowers have turned ras to the or O position switch the circuit breaker fuse disconnect to the OFF or O position Tum the HEAT 52 lo the 22 CAUTION O In case of power failure turn all switches to the OFF position and wait for the HEAT light to turn on 28 position open the oven window and remove the product After the power has been restored perform the normal startup procedure IF THE OVEN WAS SWITCHED OFF FOR LESS THAN 5 MINUTES WAIT FOR AT LEAST FIVE MINUTES BEFORE RE STARTING THE OVEN The burner will not operate and gas will not flow through the burner without electric power No attempt should be madeto operatethe oven during a power failure Display HEAT ON Shows the Set Point Light or the Actual Tem Lights when the SECTION 3 OPERATION perature in degrees burner is in Fahrenheit F or operation Celsius C SP LOCK Light Lights when the set point is locked out from changes This setting can only be changed by 774 Middleby service personnel 748 Marshall HEAF N OVERTEMP FSET Light ACTUAL lt TEMP Lights when the oven temperature is greater than 650 F 343 C Refer to Quick Reference Troubleshooting in this section Tempe
7. Mid BLE FOLLOWING MINIMUM CLEARANCES LEFT SID NCHES HES 70 BACK WALLS FOR INSTALLATION UNDER VENTILATION HOOD ONLY INTENDED FOR OTHER THAN HOUSEHOLD USE E WIRE WITH GROUND Cablage avec mise a la masse PHASE ADAPTE POUR ETRE INSTALLE SURE DES PLACHERS INFLAMMABLES ADAJACENTS A DES MURS COM BUSTILBES ET NON CO LES DEGAGEMENTS MINIMUM PARO DROITE POUES AND I ARRIERE POUCE POUR UNE INSTALLATION Ad ONE HOTTE OF D EVACUATION SEULEMENT DESTINE A USAGE AUTRE QUE DOMESTIQUE JERS EL ACCEPTED FOR USE CITY OF NEW YORK DEPARTMENT OF BUILDINGS MEA 309 83 E 46697 REV C 19 SECTION 2 INSTALLATION U S A the Canadian Electrical Code CSA C22 2 the Australian Code AG601 or other applicable regulations The supply conductors must be of the size 14 AWG copper recommended Refer to the wiring diagrams of Section 7 All gas oven electric supply connections are made viathe electrical junction box onthe rear of the oven Figure 2 12 The power lines then connect through an oven safety switch on the control console door frame to the oven circuits Opening the door interrupts electric power to the oven CAUTION Before connecting incoming power to the oven measure the voltage of each input leg to neutral The expected voltage is approximately 120 vo
8. N High Velocity Columns of Air on Food Product Air Flow From Plenum Manifold Baffle Inner Plate Manifold Series ovens used to bake pizza have four bottom fingers and two top fingers For special product baking require ments a number of other styles of fingers and finger arrangements are available from the factory NOTE Some customers have a predetermined finger arrangement Ifyou have any questions to the finger arrangement please call the factory Manifold Baffle Outer Plate Inner Plate Outer Plate Figure 1 5 Air Fingers Showing High Velocity Columns of Air Formed During Passage Through the Inner Plate and Outer Plate to Heat the Food Product SECTION 1 DESCRIPTION COMPONENT FUNCTION Figure 1 6 Cooling Fan Blower Motor E se 55 9 35 O gt gt O O e 22 6 SS 5 C ir 22 c X D lt O Optional Adjustable Eyebrow 5 a 5 Controller Conveyor s Rear Stop Conveyor Removable Conveyor Assembly Control Console Window Legs Removable Crumb Pan with single or Locking Casters Rear casters are not locking casters Figure 1 6 PS540 Series Oven Components Locations with triple ovens double ovens Outriggers SECTION 1 DESCRIPTION Ill COMPONENT FUNCTION A Conveyor Motor
9. Figure 4 2 Conveyor Belt and Crumb Pan Cleaning MAINTENANCE MONTHLY NOTE The oven interior may require cleaning more than once a month depending on the volume of baking To cleanthe interior you have to disassemble some parts of the oven When cleaning your Series PS540 Oven note the following PRECAUTIONS 1 Do not use excessive water or saturation of oven insulation will occur 2 Do not use a caustic oven cleaner or the aluminized finger manifold surfaces will be severely damaged When cleaning your oven first remove all heavy debris with a vacuum cleaner Use damp cloth for light cleaning For heavier cleaning of baked on grease and carbon Blower Cooling Fan Motor Optional Adjustable Eyebrow Conveyor Rear Stop Conveyor End Stop Removable Conveyor Assembly Window Legs E with single or 2 double ovens Locking Casters Rear casters are not locking casters N N N IN N N ANN Outriggers with triple ovens SECTION 4 MAINTENANCE deposits use a non caustic cleaner that will not react with the aluminized finger manifold surfaces You can order non caustic cleaner from your local autho rized Middleby Marshall Parts Distributor in the quantities listed below Quantity 27170 0244 Case of Quarts 6 27170 0246 Case of Gallons 4 A Removing Conveyor From Oven For Cleaning 1 Remove crumb pans as shown in Figure 4 2
10. will initially set up the oven purge circuit After approximately 30 seconds the burner lights After the burner is lit a flame sensor sends a signal to the ignition module to stop the spark The burner will run unless the flame sensor does not detect a flame or the heat switch is turned to the OFF or O position The HEAT switch is in series with the burner blower motor centrifugal switch the high temperature safety switch and the blower fan air pressure switch All three safety switches must be closed for gas to flow and the burner to light D Temperature Controller The temperature controller is a solid state on off type to maintain the operator set temperature The temperature controller continuously monitors the oven temperature and turns on the modulating solenoid valve in a gas heated oven The heat is on for the time required to maintain a constant oven temperature The temperature controller contains a low limit switch which allows the oven to cool down to 200 F 93 C before shutting off the blower A high limit indication ALM 1 will appear on the display if the oven reaches 650 F 343 C Temperature Controller Conveyor Speed Digital Control Conveyor Speed Control Module Blower Switch Heat Switch Conveyor Switch Figure 3 2 Interior View of Machinery Compartment and Control Console SECTION 3 The on off switch for the conveyor motor is
11. 1 GE See Figure 4 54 Figure 4 55 7 SOs 1 Figure 4 56 47 SECTION 4 KEY SPARE PARTS An oven can be purchased with a Key Spare Parts Kit parts that can reduce serious downtime and loss of Figure 4 56 The kitcan be purchased whentheovenis production if a failure occurs ordered or later from a Middleby Marshall Authorized Parts Distributor The kit contains many of the crucial Placement parts for this kit can be purchased from your Middleby Marshall Authorized Parts Distributor PS540 SERIES GAS OVEN KEY SPARE PARTS KIT p n 36805 Figure 4 56 ITEM PART NO ENGLISH DESCRIPTION QUANTITY 1 47321 Temperature Controller 1 2 44687 Blower Fan Motor 1 3 47797 Conveyor Drive Motor 1 4 3 337 Conveyor Speed Control 1 5 33812 3 Thermocouple 1 6 41647 Module M420 1 7 50275 Burner amp Motor Assembly 1 8 50239 Ignition Control Module kit 1 Figure 4 56 Key Spare Parts Kit p n 36805 48 5 TROUBLESHOOTING SECTION 5 TROUBLESHOOTING PROBLEM PRODUCTS ARE OVERCOOKED OR UNDERCOOKED Check for correct setting on tempera ture controller Check for correct setting of conveyor speed control Turn temperature control to correct setting Verify the food preparation process If products still cook incorrectly call your Middleby Marshall Set the conveyor speed control at correct setting Service A
12. 5 NOTAN 0801 00098 2 06 av 1109 14 5 11145 100 11020 96 GE ZE 15 OE Oc 11 cL SIN3LI SIONTONI 945 ASSV3AIHQ 3INVH3J HOA3ANOO 9600 00767 8c 84 5 1 1455 LAVHS 43101 HOA3ANOO LNOHJ 460 007 7 20 848 LAVHS HV3H 9691 00098 9 JZNOH8 LV 13 L000 G 712 2 Sc 14 9 93 84 SWALI SJANTONI 995 A 18IN3SSV LAVHS 80446 1 170 00018 2 c 1 5 LAVHS 0 lt 00 00698 2 HOA3ANOO MIYOS 8001 00098 2 Lo NOILLdlH2S3G N d ALO C N 8 6 X v 9 5 8 000 052 2 05 LN3WNG13M 4 HOA3ANOO 3 13 1dI NOO 00 00616 61 9 Sc 22 08 6L 71 SAIL SSGNTONI AIINISSV 4 HOA3ANOO 2600 0076 81 M389S M GO 0 Z L3M20HdS 3AIHQ HOA3ANOO E000 62222 91 11 91 8 2 SS 2000 9 11 r 91 4 HOA3ANOO 3 LONId 8650 00658 2 51 9 8 6L OL SL SL SIN3LI 83 0 ASSY 445 HOASANOOSNIG 1033 13 1d OO 2600 0076 rL 20 1 106 48 1L392OHdS 7000 69 1 el 8 9 102 52 13 14308 45 000 6SL22 21 2 1 92 885 AT8IN3SSV H3TIOH LS00 00v6t St 848 A18IN3SSV H3TIOH 0400 00767 01 NMOHS AnM0Id TOHLNOD HOA3ANOO 29209 2 6 dZ 26 01 84334 LAN LLELOOZ r 8 CE X 42 1 LHOIH
13. 7 Reconnect the outside master links both sides of oven 8 Replace all parts removed from the oven Crumb Mounting Bracket Figure 4 34 7 Lower End Plug Figure 4 36 42 4 Reassemble conveyor drive chain cover and then reassemble the bottom cover to the drive chain cover Install both upper end plugs Figure 4 37 SECTION 4 MAINTENANCE Ill MAINTENANCE EVERY 3 MONTHS WARNING Shut OFF all electrical power and lock tag out the switch before attempting maintenance work Shut OFF gas supply to oven NOTE It is recommended that the 3 month mainte nance be performed by an authorized Middleby Marshall technician A Cleaning the Blower Fan Motor To gain access to the blower fan motor open the control cabinet door by removing the three screws Clean the motor burnerblower motor the conveyor drive motor and the surrounding area using either compressed air or CO Thoroughly blow out the motor compartment and vents inside the motor Figure 4 38 Failure to do this can cause premature failure of blower fan motor CAUTION Not cleaning the blower fan motor properly can cause premature failure Fan Motor Blow Out In This Area Conveyor D C Motor Burner Blower Motor 8 14 he 2 uM T SAH 4 o Y gt Figure 4 38 43 SECTION 4 B Electrical Terminals Open the control cabinet door b
14. Page SECTION 1 MODEL IDENTIFICATION SERIES PS540 ELECTRICAL SPECIFICATIONS 2 Il PRINCIPLE OF AIR FLOW 3 A Heat Transfer and How It Works 3 Il PRINCIPLE OF AIR FLOW Continued 4 B All FINgerS GG GR 4 Ill COMPONENT FUNCTION 5 A Conveyor Motor and Conveyor Belt 6 B Blower Fan an 6 C Gas BUNE eine 6 PE ie m 6 E Cooling 7 F Air Fingers and Blank Plates See Figure 1 9 8 SECTION 2 cet 9 5540 INSTALLATION REQUIRED KITS AND EQUIPMENT 10 PARTS LIST FOR SERIES PS540 GAS OVEN INSTALLATION KIT 50633 10 PARTS LIST FOR PS540 SERIES SINGLE OVEN OPTION BASE W 15 LEGS 8 TOP P N 34832 11 PARTS LIST FOR PS540 SERIES DOUBLE OVEN OPTION BASE W 6 LEGS CASTERS 8 TOP P N 34633 12 PARTS LIST FOR PS540 SERIES TRIPLE OVEN OPTION BASE w OUTRIGGERS amp TOP P N 34831 13 RESTRAINT CABLE INSTALLATION 16 UTILITY ROUGH IN DIMENSIONS AND POSITIONING FOR PS540 SERIES OVENS 17 ELECTRICAL SAFETY SWITCH 17 ELECTRICAL SPECIFICATIONS
15. 2 Remove upper and lower end plugs from each end of oven by removing the two wing screws from each end plug 3 Remove the conveyor end stop and the conveyor rear stop Figure 4 3 Removable Air Fingers Inside Baking Chamber Conveyor Motor Machinery Compartment Temperature Controller Conveyor s Speed Control s Control Console 2 4 Removable Crumb Pan N Figure 4 3 33 SECTION 4 lt J li M ERE gt g Figure 4 4 ZU Figure 4 5 4 Remove conveyor drive chain cover as shown 5 Remove tension from drive chain by lifting and pushing the conveyor slightly into the oven Remove drive chain from conveyor drive sprocket as shown NOTE The split belt conveyor assembly can only be removed from the drive end of the oven 6 Begin sliding conveyor out of the oven as shown B Z Figure 4 7 7 Continue sliding the conveyor completely out of the oven fold itin half and then place it to the side for cleaning Be careful not to bump drive sprocket while handling conveyor or damage may result to drive shaft NN NW Figure 4 8 CAUTION Be careful not to bump the drive sprocket while handling the conveyor to avoid damaging the drive shaft 34 SECTION 4 MAINTENANCE a B Air Fingers Disassembly For Cleaning 1 Asthe airfingers are removed us
16. HARDWARE 7 8 9 10 11 12 13 amp 14 5 SECTION 2 INSTALLATION Figure 2 4 Model PS540 Triple Oven Option Base with Outriggers and Top PARTS LIST FOR PS540 SERIES TRIPLE OVEN OPTION BASE w CASTERS amp TOP PART NO 54606 45209 22290 0009 22290 0010 45206 45205 220373 21416 0001 21422 0001 21172 0004 21216 0018 21416 0003 21426 0004 21256 0008 22450 0228 33486 P N 51139 DESCRIPTION COMPLETE BASE WELDMENT QUAD OUTRIGGER WELDMENT SWIVEL CASTER W BRAKE FLAT PLATE SWIVEL CASTER FLAT PLATE INSERT QUAD ADJUSTMENT FOOT SPACER QUAD CASTER 3 8 16 x 1 HEX BOLT SST 3 8 FLAT WASHER SS 3 8 SPLIT LOCK WASHER ZP 3 8 16 NYLON INSULATED LOCKNUT ZC 1 2 13 1 1 4 18 8 HEX CAPSCREW 1 2 18 8 FLAT WASHER 1 2 18 8 LOCK WASHER SCREWS FOR TOP 10 32 x 3 8 18 8 SL TRUS S RESTRAINT CABLE ASSEMBLY TOP COVER 304 PANEL 13 2 INSTALLATION Figure 2 5 MODEL PS540 SINGLE OVEN DIMENSIONS j 2 0 y que 1 GAS INLET 3 3 2 ELECTRICALJUNCTION BOX 1359 mm 11 mu sw 0 een RECOMMENDED MINIMUM CLEARANCES y Hear of Oven to Wall 6 150mm End of Oven to Wall 0 qn
17. MNITH3ISVIN 8100 00688 CE X MNI1H3LSVIN 1100 00666 9 CE X 42 1 1431 157 9100 006 G 8100 00658 1 2100 00625 L 9100 00658 1 SNIV LNOO 28219 r L3 L3HIM SS HOASANOO 00 006 dS 9 98 2 X St 45 1 1739 9220 0927 2 9 Zk 6 8 45031 s3an1oxa 408 09 09 11145 97905 NOLLAIHISIA N d ALO 1148 11145 61 SECTION 6 PARTS LIST RT Q GA 54 NN 29 N 62 SECTION 6 PARTS LIST all X SSOHO 99204 22 ONIHShg 27787 LZ wel X all X 331 19997 02 NOISS3HdlNOO ONLLLIA 888 2 61 dINV10 3 14 ASSY 18 0 000 6 8l 13MSV9 16696 21 LAN 8 1 20006 91 X AAOLNHS SVD 6000 91 LEZ 51 9000 09922 JINAON JAYA 1 17917 el ATS WASSV uaNunasvo 9 809 21 SSVd A8 471 89209 LL LAN 2 1 7000 91055 01 099584 LOZE 3NvdOHd H3Ntin8 NIVIN TIO 068 17909 6 09984 6861 IVENLVN H3Nuna8 NIYA TIIHG 3014180 07909 8 860 IWHNLVN SSVd A8 509 680 SSVd A8 698 9000 42 9 NMOHS LON 09884 LIM OL IVENL
18. O c O O c c gt O DN I EN D D gt 6 N 2 EA O 2 48 c m 5 gt O c Oo D 22 58 D lt 5 2 O O o O c z O E 5 0 gt gt c O C O 22 9 2 0 9 2 X O st LO 0 2 O lt stacked single ovens triple oven consists of two Figure 1 1 Single PS540 Oven Figure 1 2 Double PS540 Oven Figure 1 3 consists of three stacked single ovens The lower oven is mounted on a base pad with short legs and casters On a double or triple oven the ovens operate completely independent All ovens use identical controls and compo nents One oven can be cleaned or serviced while the others are operating WARY 1 NN NO N N NON N NW NON 0017 WW NN N 1 N N NN N N Figure 1 3 Triple PS540 Oven SECTION 1 DESCRIPTION 5540 SERIES OVEN SPECIFICATIONS Conveyor Belt Width 32 813mm Heating Zone Length 40 1 2 10
19. SL SIN3LI SIONMIINI ASSVHOASANOODNIGIOS SLA IdWOO 00 00 68 el 20 1 181 468 LIADOYAS 5000 19122 21 8 G LOL S amp 13MOOHdS 2000 19122 GIS A18W3SSV H3110H 0900 0096 01 NMOHS TOHLNOO 59505 6 dZ 86 01 Sd3M LAN LLELOOZ 8 ZE X LHOIH ANI 15 8100 006 ZE X 15 1100 00666 9 ZE X 42 1 1431 MNI1H31SVIN 9100 006 G 8100 00658 1 7100 006 9100 00658 1 SNIVLNOO NI 08219 r L3 L3HIM SS HOASANOO 28200 00688 S 11 8 5 708 X ZE 1139 HOASANOD G220 09r22 2 18 9 21 6 8 2 SAILI SIANTOXA 408 HOASANOO 3 1ONIS 2 0 NOLLAIHISIA N d HOA3JANOO 59 SECTION 6 PARTS LIST SECTION 6 PARTS LIST L 0S L dHOS L HOLOIN 26427 2 LV NVd 9050 00698 2 OV dHOA3ANOO SLO IS M NVd INNHD 99020 00696 2 6 1X3 HOA3ANOO JAIS MOVE 3015 8710 00695 85 1X3 HOA3ANOO GN3 4016 3015 2011 00095 16 1NdIAG I3M 3AIHC 3INVH4d HOA3ANOO 313 Id NOO 9200 00646 95 AAO 1NOY3 13X008dS 00 00696 96 dS ASSV1JVHS3AIHTHOA3ANOO LNOHH 8100 00767 VE LAVHS SAIC HV43H NNOO c600 006S 55 ve Y 66 Sc SIN3LI SIONTONI 848 ATS8IN3SSV LAVHS JAYA ce 45 NO TAN LEGL OOOSE LE
20. 26 Power 2 26 Shutdown Procedure 26 A Daily Startup Procedure 28 IV NORMAL OPERATION STEP BY STEP 28 V QUICK REFERENCE TROUBLESHOOTING 30 SECTION 4 MAINTENANCE MAINTENANCE DAILY 32 A EXISrIO0 get 32 un ae 32 Conveyor Belt 32 D Crumb Pang uu otro en 32 Es WINCIOW 32 I MAINTENANCE MONTHLY 33 A Removing Conveyor From Oven For Cleaning 33 B Air Fingers Disassembly For Cleaning 35 C Cleaning the Window 36 D Reassembly of Air Fingers 36 E Reinstall End Plugs 39 F Conveyor Reassembly Into Oven 40 Checking Conveyor Belt Tension 40 Conveyor Belt Link Removal 41 Replacing Conveyor Belt 42 J Attaching Drive Chain 42 Ill MAINTENANCE EVERY MONTHS 43 A Cleaning the Blower Fan Motor 43 B Electrical Terminals
21. Installation Parts 10 SECTION 2 INSTALLATION HARDWARE BAG 5 6 7 amp 8 Figure 2 2 Model PS540 Single Oven Option Base with Legs and Top PARTS LIST FOR PS540 SERIES SINGLE OVEN OPTION BASE w 15 LEGS amp TOP P N 34832 ITEM NO QTY PART NO DESCRIPTION 1 1 37900 0025 COMPLETE BASE WELDMENT 2 4 37900 0024 PLATE LEG WELDMENT 3 2 22290 0009 SWIVEL CASTER W BRAKE FLAT PLATE 4 2 22290 0010 SWIVEL CASTER FLAT PLATE 5 32 220373 3 8 16 x 1 SCREW SST 6 32 21416 0001 3 8 FLAT WASHER SS 7 32 21422 0001 3 8 SPLIT LOCK WASHER ZP 8 4 21256 0008 SCREWS FOR TOP 10 32 x 3 8 18 8 SL TRUS 5 9 1 22450 0228 RESTRAINT CABLE ASSEMBLY 10 1 33486 TOP COVER 304 PANEL 11 2 INSTALLATION HARDWARE BAG 5 6 7 amp 8 209 9 Figure 2 3 Model PS540 Double Oven Option Base with Legs and Top PARTS LIST FOR PS540 SERIES DOUBLE OVEN OPTION BASE w 6 LEGS CASTERS amp TOP P N 34833 ITEM NO QTY PART NO DESCRIPTION 1 1 37900 0025 COMPLETE BASE WELDMENT 2 4 37900 0102 PLATE LEG WELDMENT 3 2 22290 0009 SWIVEL CASTER W BRAKE FLAT PLATE 4 2 22290 0010 SWIVEL CASTER FLAT PLATE 5 32 220373 3 8 16 x 1 HEX SCREW SST 6 32 21416 0001 3 8 FLAT WASHER SS 7 32 21422 0001 3 8 SPLIT LOCK WASHER ZP 8 4 21256 0008 SCREWS FOR 10 32 x 3 8 18 8 SL TRUS 5 9 1 22450 0228 RESTRAINT CABLE ASSEMBLY 10 1 33486 TOP COVER 304 PANEL 12 2 O OO 0 N
22. NOTES 70 WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death Read the installation operating and maintenance instructions thoroughly before installing or servicing this equipment NOTICE During the warranty period ALL parts replacement and servicing should be performed by your Middleby Marshall Authorized Service Agent Service that is performed by parties otherthan your Middleby Marshall Authorized Service Agent may void your warranty NOTICE Using any parts otherthan genuine Middleby Marshall factory manufactured parts relieves the manufacturer of all warranty and liability NOTICE Middleby Marshall reserves the right to change specifications at any time Commercial Food Equipment Service Association Middleby is proud to support the Commercial Food Equipment Service Association CFESA We recognize and applaud CFESA s ongoing efforts to improve the quality of technical service inthe industry Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 USA 847 741 3300 FAX 847 741 4406 24 Hour Service Hotline 1 800 238 8444 www middleby com THE MIDDLEBY CORPORATION o Middleby 727258 Marshall
23. both the BLOWER db and HEAT 52 Switches are in the ON 1 position If the oven still will not heat turn the HEAT 382 BLOWER and CONVEYOR switches to the OFF position Wait for AT LEAST FIVE MINUTES before restarting the oven the Daily Startup procedure Check that the Set Point is above 200 F 93 C Turn the oven to the OFF or O position and allow it to cool Disconnect electrical power to the oven Refer to Section 4 Maintenance for instructions on reassem bling the air fingers Turn the oven to the OFF or O position and allow it to cool Disconnect electrical power to the oven Check if the conveyor is blocked by an object inside the oven to Section 4 Maintenance for instructions on checking the conveyor and drive chain tension Check that the set temperature and bake time settings are correct THESE STEPSFAIL TO RESOLVE THE PROBLEM CONTACT YOUR LOCAL MIDDLEBY MARSHALL AUTHORIZED SERVICE AGENT A SERVICE AGENCY DIRECTORY IS SUPPLIED WITH YOUR OVEN SECTION 4 MAINTENANCE SECTION 4 MAINTENANCE WARNING Possibility of injury from rotating parts and electrical shock exist in this oven Turn off and lockout or tagout electrical supply to oven s before attempting to disassemble clean or service oven s Never disas semble or clean the oven with the blower switch or any other part of the oven turned on WARNING Be
24. d Control End of Oven to Wall 0 47 5 16 1202 mm 33 7 8 860 mm 14 SECTION 2 INSTALLATION Figure 2 6 MODEL PS540 DOUBLE OVEN DIMENSIONS 53 1 2 3 1359 mm 51 1 4 1302 I III IIII i 18 40 1 2 1028 76 1 2 1943 80 2032 60 7 8 1546 47 3 8 1203 mm 2 m 24 13 16 630 mm 12 1 2 318 mm 6 1 2 Y Y Y 165 mm 57 13 16 1468 mm 15 ELECTRICAL JUNCTION BOX RECOMMENDED MINIMUM CLEARANCES Hear of Oven to Wall 6 150mm Non control End of Oven to Wall 0 Control End of Oven to Wall 0 20 3 4 2 INSTALLATION Figure 2 7 MODEL TRIPLE OVEN DIMENSIONS 1 GAS INLET mm 5 2 ELECTRICALJUNCTION BOX 3 RECOMMENDED MINIMUM CLEARANCES Rear of Oven to Wall 6 150mm 111111 m Non control End of Oven to Wall 0 Control End of Oven to Wall 0
25. lt L LLI gt 2 u 0 S LO 3 st LC N ting talla Y 2 2 7 9 gt 3 5 wu a Q lt Model PS540G THN WAN NN Ins PS540 Ser N JE Q X Q 10 06 Part 50664 30 00 PS540 Triple Double PS540 2006 Middleby Marshall Inc WARNING FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death Read the installation operation and maintenance instructions thoroughly before installing or servicing this equipment WARNING POST IN A PROMINENT LOCATION THE EMERGENCY PHONE NUMBER OF YOUR LOCAL GAS SUPPLIER AND INSTRUCTIONS TO BE FOLLOWED IN THE EVENT YOU SMELL GAS INSTRUCTIONS TO BE FOLLOWED IN THE EVENT THE USER SMELLS GAS SHALL BE OBTAINED BY CONSULTING YOUR LOCAL GAS SUPPLIER IF THE SMELL OF GAS IS DETECTED IMMEDIATELY CALL THE EMERGENCY PHONE NUMBER OF YOUR LOCAL GAS SUPPLIER THEY WILL HAVE THE PERSONNEL AND PROVISIONS AVAILABLE TO CORRECT THE PROBLEM NOTICE The warranty is NOT VALID unless the oven is installed
26. on the control panel Also on the control panel is the digital conveyor speed control The digital control can be adjusted from 3 min to 30 min bake time conveyor speed Refer to Figure 3 3 Conveyor speed is measured by the amount of time it takes for an item to go through the bake chamber of the oven MEASURING CONVEYOR SPEED See Figures 3 4 and 3 5 To check conveyor speed place a product item at the entrance end of baking chamber as shown Time how long it takes for the leading edge of the item to go from the entrance end of the baking chamber to the exit end This should be the conveyor speed shown on the conveyor speed digital control NOTE In Figures 3 4 and 3 5 the oven shownis with the conveyor running right to left Minutes Seconds Figure 3 3 Conveyor Speed Digital Control WARNING The burner will not operate and gas will not flow through the burner without electric power No attempt should be made to operate the oven during power failure N WARNING Possibility of injury from rotating parts and Figure 3 4 Product at entrance end of baking electrical shock exist in this oven chamber BEGINNING OF TIMING Never disassemble or clean the oven with the blower switch or any other part ofthe oven turned or I Turn OFF or O and lockout or tagout all electrical power to the oven before attempting to clean or service this oven Figure 3 5 Product at ex
27. set incor rectly The gas burner did not light within 90 seconds of turn ing the HEAT 3 amp 2 Switch to the ON 1 position This automatically en gages a safety lockout mode The oven did not reach 200 F 93 C within 15 utes of startup and the oven has stopped heating Controls may be set incor rectly Air fingers may have been reassembled incorrectly after cleaning Conveyor may be jammed on an object in the oven or conveyor belt or drive chain tension may be incorrect Controls may be set incor rectly SOLUTION Follow the procedures under Daily Shutdown Procedures in this section to shut down the oven Contact your Middleby Marshall Authorized Service Agentto determine and correct the cause of the condition to prevent damage to the oven Check that the circuit breaker fused disconnect is turned on Check that the BLOWER 9 Switch is in the I position The burner cannot engage until the blowers are in operation Turn the HEAT 502 BLOWER and CONVEYOR a switches to the OFF position Wait for AT LEAST FIVE MINUTES before restarting the oven the Daily Startup procedure Turn the HEAT 502 BLOWER and CONVEYOR a switches to the OFF position Wait for AT LEAST FIVE MINUTES before restarting the oven the Daily Startup procedure Check that the Set Point is correctly set Check that
28. started and demonstrated under the supervision of a factory authorized installer NOTICE Contact your authorized Service Agency to perform maintenance and repairs A Service Agency Directory is supplied with your oven NOTICE Using any parts other than genuine Middleby Marshall factory manufactured parts relieves the manufacturer of all warranty and liability NOTICE Middleby Marshall Manufacturer reserves the right to change specifications at any time KEEP THIS MANUAL IN A VISIBLE LOCATION NEAR THE OVEN FOR FUTURE REFERENCE Mod le No Serial No Seri No MIDDLEBY MARSHALL NO QUIBBLE LiMITED WARRANTY U S A ONLY MIDDLEBY MARSHALL HEREINAFTER REFERRED TO AS THE SELLER WARRANTS EQUIPMENT MANUFACTURED BY IT TO BE FREE FROM DEFECTS IN MATERIAL AND WORKMANSHIP FOR WHICH IT 15 RESPONSIBLE THE SELLER S OBLIGATION UNDER THIS WARRANTY SHALL BE LIMITED TO REPLACING OR REPAIRING AT SELLER S OPTION WITHOUT CHARGE ANY PART FOUND TO BE DEFECTIVE AND ANY LABOR AND MATERIAL EXPENSE INCURRED BY SELLER IN REPAIRING OR REPLACING SUCH PART SUCH WARRANTY SHALL BE LIMITED TO THE ORIGINAL PURCHASER ONLY AND SHALL BE EFFEC TIVE FOR A PERIOD OF ONE YEAR FROM DATE OF ORIGI NAL INSTALLATION OR 18 MONTHS FROM DATE OF PUR CHASE WHICHEVER IS EARLIER PROVIDED THAT TERMS OF PAYMENT HAVE BEEN FULLY MET This warranty is valid only if the equipment is installed started and demonstrated under the supervi
29. the BLOWER BLOWER perature 3 key to show oo switch to the ON ON the 17 position O the display and for the ACTUAL TEMP light to turn This al lows you to monitor the scd LM O oven temperature as it 3 Turnthe CONVEYOR CONVEYOR rises to the setpoint ce switch to the OFF ON ON I position 4 17 22 NM E 9 Allow the oven to preheat for 10 minutes after it has reached the set point temperature 4 f necessary adjust the B DAILYSHUTDOWNPROCEDURE conveyor speed setting MIN SEC YY by pressing the or 1 Tumthe HEAT 3 amp 2 and SF HEAT BLOWER pushbuttons on the con BLOWER 99 swit veyor speed controller to change the displayed bake time OFF ON ches to the OFF 20 Y position Note that the blowers will remain in op eration until the oven has cooled to below 200 5 Adjust the temperature Middleby controller to a desired set 9370 temperature if neces Wa f SE TRG oe Make certain that there CONVEYOR Press the Set Point are products on SEE SR and Unlock keys at the conveyor inside the O the same time Wait oven Turn the CON forthe SET PT light VEYOR a switch to to turn on the OFF position e Press the Up Arrow Eua eS and Down Arrow X
30. 2 while inside the oven and then remove it This will avoid 7 The outer finger plate is stainless and may be cleaned Preaking the window by either soaking in a hot strong detergent solution or using a caustic cleaner The conveyor belt can also be cleaned in the same way Figure 4 16 D Reassembly of Air Fingers 1 Air fingers are made up of one inner plate one outer plate and the finger housing manifold Be sure to match up the markings T1 T2 etc on all the parts of the air fingers as you are reassembling Figure 4 14 Standard Upper Finger C Cleaning the Window The window can cleaned in place If it needs a thorough Figure 4 17 cleaning it may have to be removed 36 2 Reassemblethe inner plate Keep your fingers clear so you won t pinch them The inner plate of a finger will only go in one way because of its design 3 Replace the outer plate by placing your hands flat on the top of the plate and pushing down Keep your fingers clear so you won t pinch them Py 27022 587 09 Figure 4 18 4 Replace the air fingers by pushing in atthe back side Remember to replace them according to the numbers marked onthem whenthey were removed They mustgo back in the same way they came out Flange of Finger Manifold Tab on Outer Plate lt Figure 4 20 SECTION 4 MAINTENANCE _ Figure 4 19 IMPORTANT Only Fingers fit
31. 28mm Baking Area Square Feet 9 sq ft 0 84 sq m Overall Dimension Standard Single Oven w Legs 80 2032mm L x 61 5 16 1557mm W x 47 5 16 1202mm H x Overall Dimension Double Oven 80 2032mm L x 61 5 16 1557mm W x 60 15 16 1548mm H x Overall Dimension Triple Oven 80 2032 L 61 5 16 1557mm W x 77 1 2 1969mm Weight of Single Oven 925 Ib 419kg Shipping Weight 1 100 Ib 498 3kg Shipping Cube Approx 132 ft 3 74 m Operating Range 110 000 BTU hr 116 0 mJ h 27 720 kcal 32 2 kW hr Maximum Operating Temperature 550 287 Warm up Time 10 min Gas Oven Inlet Line Size 3 4 19mm ID for each oven Minimum Gas Meter Rating 450 cu ft hr 12 74m h for 1 to 2 ovens Add 180 cu ft hr 5 1m h for each additional oven Minimum Gas Pipe Size Natural must be dedicated line 2 b1mm ID for 1 2 or 3 ovens Propane must be dedicated line 2 51 ID for 1 2 or ovens Gas Pressure Inlet Test Power Natural 1 13 kPa 6 to 12 Water Column 13 8 to 29 9 mbar 0 87 kPa Propane 2 75 kPa 11 5 to 12 Water Column 28 7 to 29 9 mbar 2 39 kPa Gas Valve 0 75 19mm ID full flow gas shutoff valve installed in oven inlet gas line A separate connection and valve must be provided for each oven Recirculating Air Fan One fan at 2300 RPM Air Velocity 3000 fpm 1524 cm sec Average Bake Time 3 min O sec Bake Time minimum 30 min O sec Bake Time maximum SERIES PS
32. 540 ELECTRICAL SPECIFICATIONS Main Blower amp Control Circuit Phase Frequency Amperage Poles Wires Elements Voltage Voltage Draw 208 240V 208 240V 1 Ph 50 60 Hz 4 1 Amp 3 Pole 3 Wire 2 hot 1 grd NOTE Wiring Diagrams are contained in Section 7 of this Manual and are also located inside the oven at the bottom of the Control Panel This Manual Must Be Kept For Future Reference Il PRINCIPLE OF AIR FLOW Thefan style blower draws air into the oven plenum where itis heated The blower then pushes the hotairthrough the air fingers into the baking chamber Each air finger contains an inner plate and outer plate that form the hotair into jets distributing it across a conveyor belt on which the food product rides Air is then pulled back into the blower and the process continues The curving black arrows of Figure 1 4 show this air flow A Heat Transfer and How It Works 1 Heat constantly moves from a warm object to a cold object Heat moves using three different paths Conduc tion Radiation and Convection Conduction This path utilizes surface to surface con tact The pizza dough in contact with the pan is a good example of conduction Radiation This path hasto do with objects radiating heat Dark objects absorb heat whereas light or shiny objects reflect more heat This is the reason that the inside of a Upper Air Fingers Lower Air Fingers SECTION 1 DESCRIPTION PS540 Series Ovenis light in color To ref
33. ENTILATION HOOD The rate of air flow exhausted through the ventilation system is generally between 1400 and 2500 cu ft min 40 and 70 m min but may vary depending on the oven configuration and hood design To avoid a negative pressure condition in the kitchen area return air must be brought back to replenish the air that was exhausted A negative pressure in the kitchen can cause heat related problems to the oven components as if there were no ventilation atall The best method of supplying return air is through the heating ventilation and air conditioning system Throughthey system the air can betemperature controlled for summer and winter air be broughtin directly from outside the building but detrimen tal affects can resultfrom either extreme seasonal hot and cold temperature from the outdoors NOTE Returnairfrom fan driven system within the hood must not blow at opening of bake chamber or poor oven baking performance will result 1 25mm minimum Figure 2 10 Vent Hood ELECTRICAL CONNECTION INFORMATION FOR PS540 SERIES OVENS WARNING Authorized supplier personnel normally accom plish the connections for the ventilation system electric supply and gas supply as arranged by the customer Following these connections the factory authorized installer can perform the initial startup of the oven Checkthe oven data plate Figure 2 11 before making any electric supply connection
34. LD S531 MOGNIM 5 NJAO 53 SECTION 6 PARTS LIST 1 1110 9 23 14 LO Co lt g lt CN 22 21 INSIDE CONTROL BOX BACK WALL 20 15 16 FOR GAS BURNER amp PIPING ASSEMBLY SEE PAGES 62 amp 63 INSIDE CONTROL BOX FRONT WALL SECTION 6 PARTS LIST A INO AV1dSIG TOHLNOO WLIDIG 20972 Vez AV 1dSIG 5 WLIDIG M TOUHLNOO 9334 HOA3ANOO 15816 2 09 08 OVAtE MHVdS 62209 22 9 S 092 H3INHOJSNVH L 80126 LZ 020008214 Hald 148 1855 02 0 YAISNd NV WNDIS LGOLE 61 S 2 H3INHOJSNVH L 24817 8l OV NVA 9795 21 1 LIIATT IH 91919373 58655 91 ONFATON 8d HOLIMS 97195 91 0951 40 1 16127 HN HOLIMS MOOTHALNI 2700 12082 el OM 9 0 HOLIMS HIV 01909 2 21 V8 LINOHIO 5897 2 LL V L LINOHIO 01 VE AO LINOHIO 9606 2 6 S HINYHOJSNVHL 70912 8 13977 4000 88867 HOLIMS HOL9313S 9697 9 190749 LOV LNOO 269 2 6 1 26977 1 SNIVLNOO HOLIMS H3MO 18 LIA 02999 5 0 2 802 HO LOV INOO 1100 19082 09 096 GACTAIHS
35. M 9920 00696 2 95 1X3 HOA3ANOO ACIS MOVE 3015 8710 00695 96 1X3 HOA3ANOO QN3 4016 3015 011 00086 VE dHOA3ANOO LAVHS 3AIHQ 101 00098 55 66 SWALI S3QfYIONI MIEGWASSV LAVHS 100 00 6 ct v L F v d3OVdS NOTAN 0801 00098 2 LE LAVHS 101 00086 06 M3HOS M HVTIOO 14 5 100 11020 ce LE 02 12 61 SIN3LI SIANTONI ACIS SAIC 00 00767 8c LNANG 13M Id NOO 9200 00626 20 9 Zc SWALI S3QfYIONI 55 4 4 2200 0086 9 dHOA3ANOO LAVHS U3 0101 00055 9 M3HOS M AO L33400udS HOAJANOO 000 620 0 SWALI S3QfYIONI 55 LAVHS 4101 7100 00767 Ed IN3ING 13M Lv0 0007 2 19 19 LAVHS HOAHANOO 0200 00696 LG HOA3ANOO MIYOS 8001 00098 2 0 C N 8 9 v 1 000 v 0cc 2 61 1 9953 ALO ez cc 146 02 61 SIN3LI SHOfTTONI HOA3ANOO AIBIN3SSV aais 100 0076 81 LN3INT13M FAINVYS HOASANOO 313 1dINOO 00 00646 11 81 8 ZI SAALI SSGNIONI H3ldi A38IN3SSV 4 HOA3ANOO 2 00 00 6 91 91 8 2 SS 2000 92 1 12 51 JINVH3 HOA3ANOO 31V 1d LOAld 8650 00698 rL 92 89
36. OTES 50 SECTION 6 PARTS LIST SECTION 6 PARTS LIST 51 SECTION 6 PARTS LIST 2 2 1H3SNI LOOJ LNINLSNFAV 90598 0 0 1N3AQT3M 60598 62 T H3OVvdS 15 9 qvno 50598 82 0 lt 8 81 4 1 X El Z L SOHH MIYOS 8100 9121 8 18 8 81 2 1 H3HSVM MOOT 7000 927 LZ 8 92 8 81 2 1 H3HSVM 113 2000 9171 8 GZ OZ GALVINSNI NOTAN 91 8 6 LAN 7000 21115 91 15 LOH NOILNVO 138V1 1700 00952 ez 8 NOLLONELSNI 1010 00952 22 31V d 3NVN 200 00822 E dZ 8 H3HSVM 1774 1000 9171 2 UN 02 48 6 11145 MOOT H3HSVM 000 2512 UN 61 155 1 X 91 8 8 OVIH MIYOS 605 HUN 8l 31V1d 1V1d4 TANSt31SVO 0100 06522 11 31vdl1v143XvH8 M AMS 931599 6000 06522 2 91 1N3IAQT3M 31 dOL H 9 931 2010 006 6 9 1N3AQT3M 31V d 937 7200 00622 vi 1N3IAQT3M 3S V8 313 14AOO 90975 el HOLV1MOGNIM 1800 00v2v 21 ATINISSVHOOASSYTID 98202 IN3IAQT3M 3INVH3 MOGNIM 6010 00615 01 S 5 1 16 8 81 8 8 26 01 MIYOS 8000 9912 6 708 401 H3AOO 98755 8 MOHS3A3 16908 2 H3AOO NIVHO HOA3ANOO 9066 9 58 SS X v L 2LIOHHSM M3HOS 9000 9612 91 S A18W3SSV 31 48 1 6 4 8 03 b L OLLSV Id LAN DONIM 29995 8 A18A3SSV H3MOT 9661 2 2 Al8N3SSV H3ddn 2766 2 NOILdIHOS3G N d A
37. VN 7509 NOINN 2 1 000 1S0 2 1d 3 lddlN EX 2 1 2600 18162 3 lddlN 35010 1 7000 88155 2 10 519 09 FATWA 1OH LNOO SVD 1 72209 NOILdIHOS3G N d MALO ATEINASSV DNIdld H3NHf8 SVD 63 SECTION 6 PARTS LIST 64 SECTION 6 PARTS LIST 409 096 GACTAIHS AIGNOOOWYSHL 6 6 856 91 Qqavn9o 26715 OV NVA 9796 51 H3HSVM 4190 1 c89eV 81 99 SS LAN 7000 9612 dN AVS HHHSVM LV 13 20887 2205 01 8 8L L X 8L 91 S GH MAYOS 3NIHOVIN 9685 8 6 SS H3HSVM LV L000 9Lv 8 8 dZ 8 1145 H3HSVM MOOT 000 1 8 2 dN v X 91 8 GH MIYOS 08806191 8 9 LuOddns HOLON 24208 TSM 19 98 ONILNNOW HO LOIN 9667 dH 27 HOLOIN 28977 5 4104 ON VO HOLIMS AHV LN3INOIN L900 Lc08 2 VOL HOLIMS MOO IH3 NI 2700 12082 NOILLdlH2S3G N d ALO ININLAVANOD AYANIHOVIN 65 SECTION 6 PARTS LIST NOTES 66 SECTION 7 ELECTRICAL SCHEMATICS SECTION 7 ELECTRICAL SCHEMATICS OLvLOS 09954 ME 09 06 072 8029 67 SECTION 7 ELECTRICAL SCHEMATICS NOTES 68 SECTION 7 ELECTRICAL SCHEMATICS NOTES 69 SECTION 7 ELECTRICAL SCHEMATICS
38. acility to unload the carton s Instructions for stacking the ovens is continued in a separate manual used by Middleby Marshall Authorized Installers If you have a door wider than the carton simply move the carton into your facility and arrange an appointment with your Middleby Marshall Authorized Installer If your door is narrower than the carton then the oven will have to be unpacked Follow the directions shown in the Pre Installation Procedures Manual 2 INSTALLATION 5540 OVEN INSTALLATION REQUIRED KITS AND EQUIPMENT TYPE PS540 PS540 Single PS540 Double PS540 Double PS540 Triple OF Gas Oven Oven Option Oven Option Oven Option Oven Option INSTALLATION Installation Base w 15 Legs w 6 Legs Base w Casters w Casters Kit P N Casters amp Top Casters amp Top amp Top amp Top 50663 Kit P N Kit P N Kit P N Kit P N 34832 34833 34831 51139 PS540 Single Gas Oven 1 1 PS540 Double Gas Oven 2 1 1 PS540 Triple Gas Oven 3 1 PARTS LIST FOR SERIES PS540 GAS OVEN INSTALLATION KIT P N 50633 Two required for double oven Three required for triple oven ITEM NO QTY PART NO DESCRIPTION 1 1 22361 0001 FLEXIBLE GAS HOSE 2 1 35000 1103 CONVEYOR END STOP 3 1 35900 0148 CONVEYOR LEFT REAR STOP 4 1 50664 SERIES PS540 OWNER OPERATOR MANUAL 5 1 1002040 SERVICE AGENCY DIRECTORY 6 1 33900 0032 CONVEYOR WIRE BELT N 2 _____ S2 3 Figure 2 1 PS540 Series Gas Oven
39. and Conveyor Belt The conveyor belt is driven by a variable speed electric motor Figure 1 7 operating through a gear reducer The motor speed is controlled by a digital control The stain less steel wire belt cantravel in either direction at variable rates ranging from 3 minutes to 30 minutes this is the time that a product can take to pass through the oven B Blower Fan The blower fan is located at the rear of the oven This blower forces heated air through the air fingers The BLOWER switch must be set to ON or I for oven warmup and baking C Gas Burner Turning the HEAT switch to 1 activates the oven purge circuit After approximately 30 seconds the solid state ignition control lights a pilot burner by an electric spark This system permits the main gas valve to open only after the lighting of the pilot burner is detected by the flame sensor If the pilot flame does not light or a loss of flame occurs the main gas valve closes The main burner gas is extinguished when the HEAT switch is set to OFF or O D Window A window onthe front of the oven permits viewing the items being baked and provides access to the oven for items that do not require full baking time such as sandwiches cookies small items or cheese melting processes Blower Motor Cooling Fan Left Control Box Conveyor Drive Motor Burner Gas Control Blower Motor Valve Right Control Box Figure 1 7 Machinery Compart
40. cated at the right end a minimum clearance of 0 to a left side wall 18 to aright side wall and 6 from a back wall to air openings at the rear of the oven mustbe maintained On ovens with the machinery drive compartment located at the left end a mini mum clearance of 0 to a right side wall 18 to a left side wall and 6 from a back wall to air openings at the rear of the oven must be maintained For servicing and cleaning a minimum of 18 clearance from all walls is recommended UNLOADING Your Middleby Marshall PS540 Series Oven is shipped partially assembled It will arrive in a carton on a crate Carton size for a PS540 Series Oven is 84 2134mm Long x 58 1473mm Wide 44 1118mm High x Thecrate and carton mustbe examined before signing the Bill of Lading Report any visible damage to the transport company and check for the proper number of crates If apparent damage is found make arrangements to file a claim against the carrier Surface Interstate Commerce Regulations U S A require that the claim must initiated by the consignee within 10 days from the date that the shipment is received Pre installation Procedures Manual MM P N 88910 0009 is attached to the exterior wall of the carton This manual contains detailed instructions on unpacking and moving the oven s to the operating site When the transport company notifies you of an impending delivery arrange to have aforklift at your f
41. ce permits electric and gas service should be located nearthe control console end ofthe oven s to allow convenient access to safety switches and valves USER SUPPLIED ITEMS Figure 2 9 DESCRIPTION 2 b1mm x 27 51 x 3 4 19mm TEE 3 4 19mm x 3 76mm NIPPLE 3 4 19mm FULL FLOW GAS SHUTOFF VALVE 2 51mm x 3 4 19mm 90 REDUCER ELBOW 2 51 ID GAS SUPPLY PIPELINE NATURAL GAS 15 AMP TOGGLE SWITCH 2 POLE for GAS ITEM O O N 2 INSTALLATION Il VENTILATION GUIDELINES A mechanically driven ventilation system is required for the PS540 Series Middleby Marshall conveyorized gas ovens The minimum hood canopy dimensions are out linedbelow Local codes and conditions vary greatly from one area to another and must be complied with Following are the suggested requirements for good ventilation Please re member these are recommendations or guidelines you may have a special condition or problem that will require the services of a ventilation engineer or specialist Proper ventilation is the oven owner s responsibility Improper ventilation can inhibit oven performance It is recom mended thatthe ventilation and duct work be checked out every three months Grease filters in the intake ofthe hood may be required by local codes 2 51mm minimum To allow stacking of ovens 21 1 2 546mm minimum 18 458mm minimum 8 203mm minimum V
42. d its individual shutoff valve MUST be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psig 3 45kPa 2 The oven MUST be isolated from the gas supply piping system by closing its individual shutoff valve during any pressure testing of that system at test pressures equal to or less than 1 2 psig 3 45kPa 3 Ifincoming gas line pressure exceeds 14 w c 35mbar a separate regulator MUST be installed in the line on the inlet side of the safety valve for the oven CAUTION To prevent damaging the control valve regulator of the oven during initial turn on of gas the individual shutoff valve MUST be opened very slowly After initial turn on of gas the individual shutoff valve should remain open except during gas line pressure testing refer to the preceding WARNING and during necessary servicing and maintenance procedures 20 Checkthe oven data plate Figure 2 11 before making any gas supply line connections The type of gas natural or propane being suppliedto the oven must agree with data on the oven data plate Certain safety code requirements exist for the installation of gas ovens refer to the beginning of Section 2 for a list of the installation standards In addition because a PS540 Series oven is equipped with casters for accessi bility during servicing the gas line connection shall be made with a connectorthat complies with the S
43. e a felt pen to mark all parts of the fingers This includes the finger manifold inner plate and the outer plate refer to Figure 1 9 blank choke plate is used mark that plate also Fingers are marked in the order shown as viewed from the front of the oven The marks for an upper oven should be preceded with U example UB1 UT2 etc Standard Fingers 2 Slide blank plates straight out Figure 4 10 4 Withairfingers out place them in an upright position to remove the outer plate 5 Gently step o the lip of the finger and pull the outer plate off Figure 4 9 3 Remove air fingers NOTE Some oven users require a custom finger arrange ment where the quantity of air fingers may vary You can remove top and bottom fingers and blank plates from each or either end It is highly recommended that each finger be marked before removing so it is placed in exactly the same position when reassembled refer to step 1 SNC 29 Remove the airfingers pull the finger at the back side pull straight out Figure 4 11 35 SECTION 4 6 Toremove the inner plate pull the plate out and then up 1 Remove the window by opening the window and un screwing the window knobs from each end f 23 lt 90 Ne 2 09 Figure 4 15 4 2 Push the window the way inside the oven making sure itis clear of the frame Now turn the window sideways Figure 4 1
44. emperatue The oven is now ready for baking Power Failure In case of power failure turn off all switches open oven window and remove product After power has been reestablished follow normal startup procedure CAUTION The burner will not operate and gas will not flow through the burner without electric power No attempt should be made to operate the oven during power failure B Shutdown Procedure 1 Turn the BLOWER and HEAT switches to OFF or O NOTE Theblowers will remain on until the oven tempera ture cools down to 200 F 93 C at which time they will stop automatically 2 Make certain that there are no products left on the conveyor inside the oven Turnthe CONVEYOR switch to OFF or 3 Turn off the main gas supply valve 4 Openthe oven window SECTION 3 OPERATION TEMPERATURE LL Middleby 727248 Marshall HEAT PT ACTUAL O TEMP sP LOCK OVER TEMP CONVEYOR Figure 3 6 Control Panel 27 SECTION 3 OPERATION NORMAL OPERATION STEP BY STEP 7 Wait for the oven to heat to the setpoint temperature Higher setpoint temperatures will require a longer wait The oven can reach a temperature of 500 F 232 C in approximately 5 minutes A Daily Startup Procedure 1 Check that the circuit breaker fused disconnect is in the on position Check that the window is closed 8 Optional Pressthe Tem 2 Turn
45. fore performing any maintenance work or cleaning turn main power switch off CAUTION When cleaning do not use any abrasive cleaning materials or water spray wipe clean only Never water hose or pressurized steam cleaning equipment when cleaning this oven NOTICE If the oven is to be removed from its installed location for servicing perform the following procedure Switch off the oven and allow it to cool Do NOT service the oven while it is warm Shut off main manual gas valve and disconnect gas connector from oven Turn off main circuit breakers and disconnect connector from oven Turn the adjustable legs to put weight on the casters Move oven to desired location for servicing When servicing is complete move oven to original location Adjust legs to level oven and take weight off casters Connect electrical and gas connectors to oven Turn on manual gas valve Turn on main circuit breakers Follow normal startup instructions 31 SECTION 4 MAINTENANCE DAILY A Exterior Everyday you should clean the outside of the oven with a soft cloth and mild detergent WARNING Never use a water hose or pressurized steam cleaning equipment when cleaning the oven B Cooling Fan 1 TWO COOLING FAN GRILLES AT THE REAR OF EACH OVEN CONTROL COMPARTMENT MUST BE CLEANED DAILY Clean grilles with a stiff nylon type brush 2 Checkthe air in
46. gency PROBLEM OVEN DOES NOT HEAT Check to see if both BLOWER switch and HEAT switch are in the ON or position If oven does not heat call your Middleby Marshall Service Agency PROBLEM BLOWER MOTOR IS RUNNING YET LITTLE OR NO AIR BLOWS FROM AIR FINGERS Air fingers reassembled incorrectly after cleaning Assemble air fingers correctly after cleaning Hefer to Section 4 procedure or call your Middleby Marshall Service Agency PROBLEM OVEN BLOWER AND CONVEYOR OPER ATE YET THE OVEN IS NOT HEATING Reset the temperature controller to a new setting above 200 F after turning the BLOWER switch to off for 30 seconds Start the oven again If the oven still does not heat call your Middleby Marshall Service Agency PROBLEM CONVEYOR WILL NOT HOLD PROPER SPEED OR WILL NOT RUN AT ALL Check whether the conveyor is jammed on something in oven Check for proper tension of conveyor drive chain and conveyor belt Refer to Section 4 for correct procedure Check that the conveyor drive sprocket is tight If conveyor still does not run correctly contact your Middleby Marshall Service Agency PROBLEM OVEN DOES NOT TURN ON WHEN ITS SWITCHES ARE TURNED ON Check that all electric supply switches are set to the ON or position Then start the oven If oven still will not start contact your Middleby Marshall Service Agency 49 SECTION 5 TROUBLESHOOTING N
47. he oveninstallation must conform with local codes or in the absence of local codes with the National Fuel Gas Code ANSI 2223 1 latestedition The oven when installed must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code NEC or ANSI NFPA 70 NOTE In Canada the oven installation must conform with local codes or in the absence of local codes with the Natural Gas Installation Code CAN CGA B 149 1 or the Propane Gas Installation Code CAN CGA B149 2 as applicable The oven when installed must be electrically grounded in accordance with local codes or in the ab sence of local codes with the Canadian Electrical Code CSA C22 2 as applicable NOTE For Australian installation the oven must be installed only by an authorised person in accordance with AS5601 local authority gas electricity any applicable statutory regulations and manufacturer requirements NOTE There must be adequate clearance between the oven and any adjacent combustible con struction Clearance must also be provided for servicing and for operation CAUTION It is required that the oven be placed under a ventilation hood for adequate air supply and ventilation CAUTION Do not obstruct the flow of combustion and ventilation air to and from your oven Do not obstructthe ventilation holes inthe Control Panel CAUTION On ovens with the Machinery Drive Compartment lo
48. ice this oven 23 SECTION 3 OPERATION COMPONENT INFORMATION AND LOCATION Figures 3 1 and 3 2 A Door Safety Switch The Door Safety Switch is located at the lower left side of control panel opening Opening the control panel door permits this switch to open disconnecting power to all electrical controls CAUTION Do NOT touch the wires going to this safety switch Current is always present B Blower Switch The blower switch has two positions The switch must be ON or for the burner to come on and permit the oven to warm up The fan circulates the air throughout the oven and must stay on during baking and during the cool down cycle above 200 F 93 C to prevent blower bearing damage To protect the blower motor and bearings a thermostatic override is built into the oven If the tempera ture inside the oven is over 180 F 82 C the main blower will continue to run after the blower switch is turned to the OFF or O position An air pressure switch monitors the air flow from the blower acting as a safety interlock for the burner The Burner Blower Motor Assembly Conveyor Drive Motor Door Safety Switch x i 1 3 CET High Limit 11 1101 Reset Switch Y m n m _ Gas Burner and Piping Assembly burner cannot light ifthe air switch does not sense air flow off the main blower fan C Heat Switch Turning the HEAT switch to ON
49. in the bottom row All and M1 finger cover plates have extended lips at front This extended lip will not allow these fingers to be installed inthe bottom row IMPORTANT When inserting fingers the tab on the outer plate must be in the groove as shown in Figure 4 20 There is blocking tab on the outside of the groove which will prevent inserting the finger in the groove if the outer plate is moved away from the flange of the finger manifold pL Tab on Outer Plate SECTION 4 5 Install fingers and blank plates correctly with edges interlocked and no space between edges Incorrect Too Much Space Top Finger Blank Plate Tab on Outer Plate of Finger Located in Groove Incorrect Too Top ger Much Space Blank Plate Tab on Outer Plate of Finger Located in Groove Correct Top Finger Edges Overlap Completely Blank Plate Tab on Outer Plate of Finger Located in Groove Figure 4 21 38 SECTION 4 MAINTENANCE E Reinstall End Plugs 1 Reinstall lower end plug Be sure to tighten two wing screws on the end plug 2 Reinstall conveyor 3 Reinstall upper end plug Be sure to tighten two wing CZ c screws on the end plug WIR Fe UP Figure 4 22 Blower Cooling Fan Motor Optional Removable Adjustable Air Fingers Eyebrow Inside Baking Conveyor Motor Conveyor Chamber I2 Compartment C
50. is responsible The Seller s obligation underthis warranty shall be limited to replacing or repairing at Seller s option without charge F O B Seller s factory any part found to be defective and any labor and material expense incurred by Seller in repairing or replacing such part Such warranty is limited to a period of one year from date of original installation or 15 months from date of shipment from Seller s factory whichever is earlier provided that terms of payment have been fully met All labor shall be performed during regular working hours Overtime premium will be charged to the Buyer This warranty is not valid unless equipmentis installed started and demonstrated under the supervision of a factory autho rized installer Normal maintenance functions including lubrication adjustment of airflow thermostats door mechanisms microswitches burners and pilot burners and replacement of light bulbs fuses and indicat ing lights are not covered by warranty Any repairs or replacements of defective parts shall be performed by Seller s authorized service personnel Seller shall not be respon sible for any costs incurred if the work is performed by other than Seller s authorized service personnel When returning any part under warranty the part must be intact and complete without evidence of misuse or abuse freight prepaid Seller shall not be liable for consequential damages of any kind which occur during the course of ins
51. it end of baking chamber END OF TIMING 25 SECTION 3 OPERATION WARNING OVEN MUST BE KEPT CLEAR OF COMBUSTIBLES AT ALL TIMES Ill STEP BY STEP OPERATION Control Panel On split belt ovens two conveyor speed controls are mounted on the control panel A Startup Procedures Initial Startup Check that the full flow gas shutoff valve is on This valve is located outside the rear of the oven See Figures 2 3 2 4 and 2 5 Daily Startup 1 Turnthe BLOWER switch Figure 3 6 to the ON or I position This starts the main blower fan and the cooling fan The blower circulates air through the air fingers and must stay on during the cooking or baking process 2 Check to see if the cooling fan see Figure 1 8 is operating whenthe blower switch see Figure 3 6 isturned ON or I The cooling fans cool the control components and burner blower motor The cooling fan located at the rear of the electrical control cabinet blows air into and through the cabinet Air is exhausted through the front of the cabinetandalso outthe front ofthe oven Referto Daily Maintenance Section for fan intake checking procedure IMPORTANT NOTE The cooling fan operates when the BLOWER switch is turned ON I It must operate to keep the control console below 140 F 60 C 3 Turnthe CONVEYOR switch Figure 3 6 to the ON or position This starts the conveyor belt moving through the oven Set the convey
52. le oven installations the BT U hour requirement for a single oven is tripled Appliance Connection Male Nipple 90 deg ST Elbow d Union SECTION 2 INSTALLATION VI CONVEYOR REAR STOP AND END STOP INSTALLATION Locate the conveyor rear stop and end stop in the installation kit Install the rear stop and end stop atthe exit end of the oven See Figure 2 14 To Gas Supply Pipe Full Flow Gas Shutoff Valve 24 Flexible Hose Figure 2 13 Flexible Hose Installation Conveyor Rear Stop Conveyor End Stop E Y Q gt gt lt Middleby er Marshall Figure 2 14 Installing Rear and End Stops 2 INSTALLATION NOTES 22 SECTION 3 OPERATION SECTION 3 OPERATION CONTROL FUNCTIONS Door Temperature Safety Controller Switch Conveyor Speed Control Blower Switch Heat Switch Conveyor Switch Figure 3 1 PS540 Series Oven Control Functions WARNING The burner cannot operate and gas cannot flow through the burner without electric power Do NOT attempt to operate the oven during a power outage WARNING A possibility of injury from rotating parts and electric shock exists in this oven Never disassemble or clean the oven with the BLOWER switch or any other oven control turned ON I Turn OFF or and lockout or tagout all electric power to the oven before attempting to clean or serv
53. lect more heat back onto the food product Convection This path hasto do with moving a volume of air Itexplains why hot air rises and cooler air replaces hot air An industrial application of this principle is to incorpo rate a fan to force the hot air movement which in turn increases the heat transfer to the food product Each PS540 Series Oven has a large fan style blower to move the hot air through the air fingers and onto the product to cook bake the food product most efficiently 2 Temperature is the intensity of heat at the point where itis sensed As discussed above heat flows by conduc tion radiation and convection The speed at which the heat flowsis determined by thetemperature difference between the oven and the food product The larger the difference the faster the heat flows to the item that is being baked Conveyor Belt s Window Figure 1 4 PS540 Series Oven Air Flow SECTION 1 DESCRIPTION PRINCIPLE OF AIR FLOW Continued B Air Fingers The PS540 Series Ovens are conveyorized ovens that employ vertical jets of hot air streaming from air fingers Figure 1 5 to give uniform intense heating The vertical streams of hotair provide an exceptional heattransfer rate and generally bake faster and at lower temperatures than convection hot air or infrared heating ovens A PS540 Series Oven can accommodate up to four bottom air fingers and four top air fingers Some PS540 Manifold Air Flow From Plenum
54. lot in adaptor bushing and locks onto shaft 15 Thread conveyor belts back onto frame making sure the links will be traveling in the proper direction 16 Follow conveyor reassembly instructions in Monthly Maintenance Paragraph NOTE Itisrecommendedthatthe 6 Month Maintenance schedule be performed by a Middleby Marshall authorized service technician IV MAINTENANCE EVERY 6 MONTHS A Checkbrushes on D C conveyor motor when worn to less than 1 10 2 4mm replace the brushes B Clean and inspect the burner nozzle and electrode assembly Also check your oven venting system C Checkconveyor shaft bushings and spacers Replace them if they are worn See Figure 6 5 Conveyor Exploded Drawing items 15 30 and 31 or Figure 6 6 Split Belt Conveyor items 19 23 31 35 and 36 IMPORTANT NOTICES The installation startup and changes required when changing from one gas type to another can be performed only by an authorized service technician CANADIAN REGULATIONS PROHIBIT CHANGING AN OVEN S OPERATION FROM ONE GAS TO ANOTHER Installation of replacement parts requiring access to the interior of the oven is permitted only by an authorized service technician there are any problems with the operation of the oven the authorized service technician must be called It is suggested to obtain a service contract with a manufacturer s authorized service technician SECTION 4 MAINTENANCE Figure 4 53
55. lts Any voltage reading exceeding 130 volts indicates that the supply has a high leg CONNECTING A HIGH LEG TO THE OVEN VOIDS ALL OVEN WARRANTIES Connecting a high leg to the black lead of the oven can severely damage the oven s electrical and electronic components CAUTION DO NOT CONNECT BLACK WIRE TO HIGH LEG VOLTAGE OF THE BLACK AND WHITE WIRES MUST BE NO HIGHER THAN 130 VAC Contact an electrician or the electric power supply com pany to remove the high leg from the electric supply line s to the oven In the junction box on the rear ofthe oven connect one 208 240V supply line to the brown wire terminal and the other 208 240V supply line to the blue wire terminal Connect the electric supply ground wire to the oven ground lug located in the main junction box If neces sary have the electrician supply the ground wire Do NOT use the wiring conduit or other piping for ground connections Figure 2 11 Typical Gas Oven Data Plate 2 INSTALLATION c c c c c gt c c c c c c c c c c c c c c c c c c Electrical Junction Cover Plate Figure 2 12 Junction Connection Box V GAS SUPPLY FOR GAS HEATED OVENS WARNING During gas line pressure testing observe the following precautions 1 The oven an
56. ment Components SECTION 1 DESCRIPTION E Cooling Fan See Figure 1 8 The cooling fans are located in the back of the oven These cooling fans draw air through its grille blowing it through the blower motor compartment and the control compartment into the oven top and exhausted out the front louvers 098888888883800000888090090000800000000880000888800 000000800000000000000000000000008000000000000000000 Cooling Grille Figure 1 8 Cooling Fan SECTION 1 DESCRIPTION F Air Fingers and Blank Plates See Figure 1 9 F2 Blank Plates Air Fingers 1 Blank Plates The Blank Plates are available to install on the plenum where an air finger is not required An Air Finger Assembly is made up of three parts 1 Outer Plate The Outer Plateisthe removable covering with tapered holes which direct the air stream onto the product being baked 2 Inner Plate The perforated Inner Plate is vital informing the unique air jets It must be assembled into the manifold with its holes aligned with the holes of the outer plate 3 Manifold The Manifold is the assembly which slides on tracks into the oven plenum Half Blank Plate x Outer Plate Inner Plate Blank Plate Finger Manifold Assembly Baffle Figure 1 9 Blank Plates two sizes and an Air Finger SECTION 2 INSTALLATION SECTION 2 INSTALLATION NOTE In U S A t
57. ntil shafts are clean Apply more oil to shafts then reassemble Figure 4 46 SECTION 4 6 Make sure bronze washer is in between the two halves 9 Loosen the split locking collar L Ya SB HA Figure 4 47 7 Place the idler shaft assembly back into place and reinstall the adjustment screws Figure 4 50 10 Remove drive shafts by sliding to right then lifting the left side Follow cleaning and lubricating procedures out lined in Steps 4 6 Figure 4 48 8 Loosenthe setscrew on each conveyor drive sprocket Figure 4 51 and remove sprockets 11 Reassemble conveyor drive shafts into frame mak ing sure nylon spacer is in place EIN Figure 4 49 Figure 4 52 46 12 Slide shaft assembly to right side holding assembly in place Slide split locking collar to the left side and tighten 13 Sliderearconveyor drive sprocket onto shaft Tighten the set screw this drive sprocket until it extends into the hole of the hollow shaft It should NOT touch the inner solid shaft Check to see that only the rear shaft moves whenthe sprocketis turned If both shafts move you have tightened the set screw too tight Loosen the set screw until only the rear shaft moves when the sprocket is turning 14 Insert adaptor bushing into remaining drive sprocket then place onto shaft Make sure nylon spaceris in place Tighten set screw making sure screw goes through s
58. onveyor End Stop Temperature Controller Removable Conveyor s Conveyor Speed Assembly Control s Control Console Window Pa Legs with single or Removable Crumb Pan double ovens Locking Casters Rear casters are not locking casters Outriggers with triple ovens Figure 4 23 39 SECTION 4 F Conveyor Reassembly Into Oven 1 Lift conveyor and position it in oven as shown NOTE Conveyor assembly may be inserted into either end of oven If it is to be installed from the non drive end ofthe oventhe drive sprocket assembly mustbe removed as shown in conveyor disassembly section NOTE Split belt conveyors can only be inserted from the drive end of the oven gt Figure 4 24 2 Reinstall the conveyor rear stop Reinstall the con veyor end stop Conveyor Rear Stop 777 jMiddleby Marshall Conveyor End Stop Figure 4 25 G Checking Conveyor Belt Tension WARNING Oven conveyor belt must be cool when adjusting belt Do not adjust belt if HOT 1 With the conveyor assembly in the oven stand at one end of conveyor and check tension by lifting the conveyor belt at the center of the oven chamber opening The belt should not lift higher that 3 to 4 75mm to 102mm 2 Adjust conveyor belt tension screws located on left end of oven for the 3 to 4 75mm to 102mm deflection as shownin Figure 4 26 If there is propertension p
59. or speed for the desired baking time Refer to the following Procedures E F and G 4 Set the temperature controller to the desired baking temperature See section on bake times to determine desired temperature NOTE For complete temperature controller operation instructions refer to Step C 26 5 Turn the HEAT switch Figure 3 6 to the ON or position This completes a circuit to supply electric power to the burner When an oven that has not been in operation for approximately 1 2 hour is turned on it goes through a 30 second purge cycle The burner blower motor will not operate during the time the blower fan is purging the oven After 30 seconds the burner blower motor starts which can be detected by feeling a slight vibration when touched This permits the burner to light When in operation the burner is either on low or high flame lts flame sensing electrode must be satisfied to keep the bypass and gas valves open If for some reason the bypass flame is extinguished the burner tries to relight for 90 seconds If the burner flame does not relight in 90 seconds the oven goes into automatic safety lockout To relight the oven turn the HEAT switch to OFF or O for 5 minutes Then repeat the Oven Startup procedure 6 Close front window 7 Oven will reach a baking temperature of 600 F 315 C in approximately 10 minutes Allow the oven to cycle for 30 minutes after it has reached desired bake t
60. phase 4 1 Amp draw 50 60 Hz 208 240V control circuit 2 poles 3 wire system per oven 2 hot 1 grd Do NOT use conduit for ground GAS RATING Model PS540 is 110 000 BTU hour 116 0 mJ h 27 720 kcal 32 2 kW hr MINIMUM GAS METER RATING 450 12 6m h for 1 or 2 ovens Add 180 cu ft hr 5 1 m h for each additional oven Minimum rating does nottake other gas appliances into consideration Gas consumption varies at each site Total BTU hr kcal hr must be calculated during high flame operation for each appliance to determine if the meter needs to be larger MINIMUM GAS PIPE SIZE Natural 2 51 ID for 1 2 or ovens with runs up to 200 ft 61m Must be a dedicated line Runs over 200 ft 61m consult factory Propane 2 51mm ID for 1 2 or 3 ovens with runs up to 200 ft 61m Must be a dedicated line Runs over 200 ft 61m consult factory 17 Q o Suggested dimensions shown utility code requirements supersede any factors shown Figure 2 9 Typical PS540 Series Oven s Installation GAS SAFETY VALVE A 3 4 19mm ID inner diameter full flow gas shutoff valve A separate connection and valve must be provided for each oven as shown in Figure 2 9 REQUIRED GAS SUPPLY PRESSURE Natural 6 to 12 water column 13 8 to 29 9 mbar Propane 11 5 to 12 water column 28 7 to 29 9 mbar SUGGESTED If spa
61. rature Key Press this key once to view the Actual Temperature in the Display Unlock Key Press this key together with the Set Point Key to allow the Set Point to be changed Changes can only be made for 60 seconds amp SP LOCK OVER TEMP Aa Arrow and Down Arrow Keys Press these keys to adjust the Set Point up or down If the Set Point will not change refer to Set Point Key and Unlock Key in this section 29 SET PT setpoint Light Lights when the set point is shown in the display ACTUAL TEMP Light Lights when the Actual Temperature is shown in the display Service Key Service use only Set Point Key Press this key together with the Unlock Key to allow the Set Point to be changed Changes can only be made for 60 sec onds SECTION 3 OPERATION IV QUICK REFERENCE TROUBLESHOOTING SYMPTOM light is food product is undercooked Oven will not turn on at all Oven shuts down shortly after it is turned on appears in display oven is not heating Oven will not heat Oven is operating but little or no air is blowing from air fingers Conveyor moves with a jerky motion or will not move at all Food products are overcooked or undercooked PROBLEM The oven temperature ex ceeded 650 F 343 C and the burner was automati cally shut down Electrical power may not be reaching the oven or the controls may be
62. roceed to J Attaching Drive Chain If belt is still too loose continue to step 3 below 3 conveyor belt is still not under proper tension an entire link must be removed Use the following procedure H Conveyor Belt Link Removal to remove a link If conveyor belt is under proper tension proceed directly to J Attaching Drive Chain SSS SSS Figure 4 26 Conveyor Belt Link Removal 1 Using long nose pliers an entire link can be removed with the conveyor assembly either in or out of the oven Position master links at end of conveyor as shown in Figure 4 27 Figure 4 27 2 Using long nose pliers unhook master links at left end of conveyor as shown in Figure 4 28 Figure 4 28 SECTION 4 MAINTENANCE 4 Unhook the link to be removed 5 Pull up on the belt link section and remove Do not discard the link removed as it may be used for making spare master links NOTE If a section of the conveyor belt is being replaced it should be done now Remove the links that need replacing and use the section of conveyor belt furnished in your installation kit to replace them Figure 4 30 NOTE Before connecting the inside master links notice thatthese links have a correct position Figure 4 31 The link at the right is in the correct horns up position for inserting intothe conveyorbelt Thehornsfacing down are in the incorrect position Correct m di Position
63. s Electric supply connections must agree with data on the oven data plate NOTE The electric supply installation must satisfy the requirements of the appropriate statutory authority such as the National Electrical Code NEC ANSI NFPA70 U S A the Canadian Electrical Code CSA C22 2 the Australian Code AG601 or other applicable regulations A fused disconnect switch or a main circuit breaker customer furnished MUST be installed in the electric supply line for each oven it is recommended that this switch circuit breaker have lockout tagout capability The electric supply connection must meet all national and local electrical code requirements Copper is the recommended material for the electrical supply conductors IV ELECTRIC SUPPLY FOR GAS HEATED OVENS Supply voltages for all gas ovens except one 200 220V oven for export can range from 208 to 240VAC 1 phase Ampere requirements for each oven can be handled via a fused disconnect switch or main circuit breaker NOTE The electric supply installation must satisfy the requirements of the appropriate statutory authority such as the National Electrical Code NEC ANSI NFPA70 222 MIDDLEBY MARSHALL e ELGIN ILLINOIS 60120 U S A SERIAL OF GAS Type de gaz MAA INPUT PER HOUR MAXIMUM Chauff i r heure en MAN PRESS 1 INWC rs L xi ne ALICE I saepe Sn ee FLOORS
64. sion of a factory autho rized installer Normal maintenance functions including lubrication clean ing or customer abuse are not covered by this no quibble warranty Seller shall be responsible only for repairs or replacements of defective parts performed by Seller s authorized service personnel Authorized service agencies are located in prin cipal cities throughout the contiguous United States Alaska and Hawaii This warranty is valid in the 50 United States and is void elsewhere unless the product is purchased through Middleby International with warranty included The foregoing warranty is exclusive and in lieu of all other warranties expressed or implied There are no implied warranties of merchantability or of fitness for a particu lar purpose The foregoing shall be Seller s sole and exclusive obligation and Buyers sole and exclusive remedy for any action in cluding breach of contract or negligence In no event shall Seller be liable for a sum in excess of the purchase price of the item Seller shall not be liable for any prospective or lost profits of Buyer This warranty is effective on Middleby Marshall equip ment sold on or after February 15 1995 2003 Middleby Marshall A Middleby Company Installation Date Date d installation MIDDLEBY MARSHALL INC OVEN LIMITED WARRANTY Non U S A The Seller warrants equipment manufactured by it to be free from defects in material and workmanship for which it
65. take of the cooling fan daily The best time to check is right after starting the oven IMPORTANT NOTE Thecoolingfan operates when the blower switch is turned to ON I It must operate to keep the electrical control cabinet below 140 F 60 C WARNING IF FAN BLADE IS NOT ROTATING BROKEN OR FAN ASSEMBLY IS MISSING FROM MAIN BLOWERMOTOR SHAFT DONOT OPERATE OVEN REPLACE COOLING FAN BLADE BEFORE OPERATING OVEN Serious damage could be done to the burner blower motor and or solid state electrical components if oven is operated while cooling fan is not running or vent grille is plugged 3 Using a stiff nylon brush clean control compartment vent grille Hot air from control compartment exits from this grille C Conveyor Belt Figure 4 2 Everyday just after starting the oven stand at the unloading end of the conveyor and with a brush remove food particles crumbs etc clinging to the conveyor belt brushing them into the crumb pan D Crumb Pans Figure 4 2 Hemove andcleanthe crumb pan at each end of the oven Each crumb pan can be removed by sliding it out as shown in Figure 4 2 Reinstall the crumb pans after cleaning E Window The window can be cleaned daily while it is in place Vent Grille Cooling Fan Grille 0988888889888 lala bb e d M 000000800000000000000000000000008800000000000000000 Cooling Fan Grille
66. tallation of equipment or which result from the use or misuse by Buyer its employees or others of the equipment supplied hereunder and Buyer s sole and exclusive remedy against Seller for any breach of the foregoing warranty or otherwise shall be for the repair or replacement of the equipment or parts thereof affected by such breach The foregoing warranty shall be valid and binding upon Seller if and only if Buyer loads operates and maintains the equipment supplied hereunder in accordance with the instruction manual provided to Buyer Seller does not guarantee the process of manufacture by Buyer or the quality of product to be produced by the equipment supplied hereunder and Seller shall not be liable for any prospective or lost profits of Buyer THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES WHATSO EVER SPECIFICALLY THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE The foregoing shall be Seller s sole and exclusive obligation and Buyer s sole and exclusive remedy for any action whether in breach of contract or negligence In no event shall seller be liable for a sum in excess of the purchase price of the item The Middleby Marshall logo is a registered trademark of Middleby Marshall A Middleby Company Middleby Marshall Inc 1400 Toastmaster Drive Elgin Illinois 60120 9272 U S A 847 741 3300 FAX 847 741 4406 TABLE CONTENTS
67. tandard for Connectors for Movable Gas Appliances ANSI Z21 69 in U S A or if applicable Connectors for Movable Gas Appliances CAN CGA 6 16 in Canada as well as a quick disconnect device that complies with the Standard for Quick Disconnect Devices for Use With Gas Fuel ANSI Z21 41 in U S A or if applicable Quick Discon nect Devices for Use With Gas Fuel CAN6 9 in Canada One gas line connection method is shown in Figure 2 13 however the preceding requirements must be satisfied The 90 degree elbow and the union shown in Figure 2 13 are not furnished however the flexible gas line is part of the installation kit On an oven equipped with casters a cable restraint assembly must be installed to limit the movement of the appliance without depending on the connector and quick disconnect device or its associated gas line installation Thelocation where the Cable Restraint Assembly is to be attached to the oven is illustrated in Figure 2 8 The minimum gas line pressure the input side of the full flow gas shutoff valve when the oven burner is operating on the high flame MUST be for natural gas 6 w c 14 9mbar 1 13 kPa and for propane gas 11 w c 27 4mbar 2 75 kPa Sufficient pressure must be available to provide for the maximum BTU consump tion rate for the oven 116 0 mJ h 110 000 BTU hour for each PS540 Oven For double oven installations the BTU hour requirement for a single oven is doubled For trip
68. ven to operate Grease the two 2 main blower fan shaft bearings Figure 4 43 using aspecial grease MM P N 17110 0015 lithium base high temperature grease ONLY ONE STROKE of a grease gun 1 required for each bearing Figure 4 43 Upon completing the fan belt check or replacement and the bearing lubrication reinstall the rear shroud fastening it with six screws of the rear shroud F Split belt Conveyor Shaft Cleaning It is very important that the split belt conveyor drive and idler shafts are removed from the conveyor frame for cleaning and lubrication CAUTION Use a turbine oil or light machine oil DO NOT USE WD40 or similar product These oils evaporate and cause the shafts to seize 1 Perform the conveyor removal steps described in Monthly Maintenance paragraph After the conveyor is removed lay it on a flat surface 2 Remove the two conveyor belts by disassembling the conveyor master links as described in Monthly Mainte nance paragraph H Then remove the two conveyor belts by rolling them up 45 SECTION 4 MAINTENANCE 3 Remove the conveyor adjustment bolts to allow the idler brackets to swing free Figure 4 44 4 Drop the idler shaft assembly clear of the frame through the front frame slot Figure 4 45 5 Pullthe front and rear shafts apart and apply oil to both the extended shaft and the interior of the hollow shaft Using a rag wipe oil off parts Repeat u
69. y removing the three CAUTION screws from the control cabinet door Tighten all electrical Overtighteningthe beltwillcause premature bearing control terminal screws including the electrical contactor failure and possible vibration problems A spare terminal screws as shown in Figure 4 39 belt is located inside the control compartment on the rear wall 3 Whenreplacingthe belt loosenthe tension adjustment bolts Figure 4 42 on the motor mounting bracket Next pull back onthe motor Retighten adjustment bolts Do not overtighten because the fan bearings may be damaged Figure 4 39 C Ventilation Figure 4 41 Check that the air circulation throughout the oven is not blocked and is working properly D Checkingthe Blower Fan Belt 1 Checkthe main blower fan belt for proper tension and wear To gain access loosen the six screws Figure 4 40 of the rear shroud and lift shroud cover up and off 2 The fan belt should deflect no less than 1 25mm at the center Figure 4 41 and have no cracks or excessive acces wear Adjustment Bolts Figure 4 42 008198888888800000888800990009800000000080000980800 000000800000000000680000000000008800000000000000000 Figure 4 40 44 E Blower Fan Shaft Bearing Lubrication CAUTION Over greasing damages the bearing seals and accelerates grease loss which shortens bearing life Wipe off any excess grease on and around the bearing Reinstall the rear shroud to allow the o

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