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Middleby Marshall Oven PS360 User's Manual

1. 177 Min Input R Run silver 185V 10VA Oulput red _ 240V Max input Pilot ilo Ignilor Gensor Thormo couple purp purp wht NOTE All wiras are to be 12 No 18 AWG Wire Gauge unless olherwise spacilied Control Door Interlock Sw Primary 230V 5 Push Pull Secondary 115V Motor Conlactor Conveyor Motor RPM Pick up Combination Valve _ anash gaear n A 5 ove 200 F ower 93 C Switch Switch N O High Limit High feta Centrifugal Switch Centrifugal Switch 343 C LH Blowe RH Blower 0 20ma Oulpul RTE EOE A REOS 4 24VAC D NENNEN Oht __ 24 10 24906 mn dd esee em 24V Modulating Transformer 65VA s High Flamo Primary 230V Burner Temperatura valve Secondary 24V Air Spark Controller 2A Pressure Circuit Breaker Switch Modulating ignition Module Ampliller orn Burner Blower Motor red PS360EWB gas oven with Midco burner and early temp control 32571 208 240V main blower motor and control circuit 208 240V 50 60 Hz 1 Ph 2 pole 3 wire supply 2 hot 1 ground SINVHOVIO ONISIM 0819 NOLLO3S 208 240 RED L1 62 60 HZ NOTE ALL WIRES ARE TO BE
2. 174 Pressure conversions 174 Pressure conversion 175 Ohm s Law equation 175 Common electrical wiring diagram symbols 176 SECTION 1 SEQUENCE OF OPERATION GAS OVEN SEQUENCE OF OPERATION SECTION 1 SEQUENCE OF OPERATION D Blower Switch Electrical Supply Gas heated ovens operate on 208 240V single phase Standard incoming power configurations are 1 4 wire system PS200 series PS310 360 series PS570 PS570S 2 single phase 208 240V sup ply hot lines 1 neutral and 1 ground 2 3 wire system PS360WB70 PS360EWB PS555 PS570G PS536 2 single phase 208 240V sup ply hot lines and 1 ground For all wiring configurations the voltage when measured from either hot line to neutral should never exceed 130V Door Switch Closing the control cabinet door or machinery com partment door as appropriate for the oven model will close the door switch and allow the oven to operate Note that the electrical systems will still be live if the switch is open although the oven cannot operate The door switch has a bypass position to enable ser vice operation with the door opened When the door is open grasp the switch actuator and pull it out as far as possible This will close the door switch and pe
3. right Ovens with only two 9 0 2 Q O O Q 7 thermocouples will have a single set of leads on the left terminal block instead of the two sets that are Shown Pd To temperatur 7 d ome LC HG high limit To ground To temperature controller To ground To mounting screw control module erminal on temp controller terminal on temp for high limit controller controller control module NOTE This configuration m shows leads for three temperature sensing thermocouples two on the S left side and one on the Q Q Figure 146 Thermocouple Wiring PS570S Late Right to Left Conveyor Left White Red Ground White Red Red White Ground Right Terminal hi lim hi lim leads all temp temp temp temp leads Terminal Block 2 2 Block lial Tal NOTE This configuration shows leads for three temperature sensing thermocouples two on the right side and the l left Ovens with only two 9 0 0 D temperature sensing O O thermocouples will have a single set of leads on the y Pa right terminal block that are shown To high limit lt NS To temperature N control module To m
4. 1 1 2 MODULATING VALVE 46 68 Hi HZ 2 LS 2 DOOR 52 PRIMARY 5 240 280v 50 60 SECONDARY 120v 200 8 5 5 31341 FEMALE RCPT 7 P N 31341 FEMALE RCPT CONVEYOR Iw CONTROLLER d ARM 51 4 POL MAGNET RIBBON CONN 52 lt 011 SOCKET LOCATIONS 24 2 4 41 lt 5 37 5 6 42 ol 44 o CONNECTS TO MALE END OF P N 32142 TC2 RIBBON CONN gt ADAPTER BOARD 32482 54 4 POLE MAGNET Hz HIGH LIMIT 1 tO RESET SKVER GREEN LIGHT LIGHT 20 CONVEYOR CONTROLLER RIBBON CONN gt PLIT BELT ONLY P N 32682 MALE REPT PIN LOCATIONS CONNECTS TO FEMALE ENDIS OF P N 44749 COPPER PAGE 1 OF 2 SPLIT BELT ONLY RIBBON CONN ADAPTER BOARD 32482 PS200R68 series gas oven with modulating valve 208 240V main blower motor and control circuit 208 240V 50 60 Hz 1 Ph 2 pole 3 wire supply 2 hot 1 ground SINVHOVIO ONISIM TVOIH LO3 13 NOLLO3S 991 P N 31279
5. ously used the older style 2 lead or 4 lead thermocouples it is acceptable to use a single chassis ground wire to the mounting screw for the terminal block See Figure 15 A good ground connection for the thermocouple s uninsulated lead is REQUIRED for proper operation New chassis ground wire To high limit To temperature control module controller SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kits 33984 and 33985 Oven Thermocouple Kit 11 01 PS555G and PS570G rear wall thermocouples with left side terminal block connections Thermocouples on these ovens are located on the rear wall They are secured in place by two screws that are inserted through the holes in the thermocouple flange The ovens are equipped with a three lead flanged thermocouple iden tical to the one in this Kit NOTE FOR HIGH LIMIT THERMOCOUPLES These ovens have a high limit thermocouple installed in the last mounting hole at the exit end of the oven The thermocouple supplied in this Kit can be used to replace ANY of the temperature sensing or high limit ther mocouples on the oven 1 Remove the rear shrouds Then remove the cover over the left blower motor This allows access to the ther mocouples on the rear wall and to the terminal block inside the blower motor compartment Note that the thermocouples on these
6. lt High Limit Conversion PS300 310 350 360 Ovens 5 99 935012 WHON N3dO Q WON NOWWOO ASNVYO 1013002 adh 91439913 suonoeuuo pyeoq 49044405 eunjejeduie Bojeuy 21 Ajddns Bunsix3 uou i SN leseH EE JOJO OL ERE EEEIE PEE TEE EHE EI KEET EELEE SIAM yw u6iH Page 7 of 8 9JIM A 9JIM Bunsix3 A3M e pg 21329 3 8 4 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 39733 High Limit Conversion Kit for PS300 310 350 amp 360 Ovens 5 99 z Middleby Marshall A MIDDLEBY COMPANY Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 USA 847 741 3300 FAX 847 741 4406 Middleby Corporation Service Hotline 1 800 238 8444 www middleby com Page 8 of 8 SECTION 3 SERVICING COMPONENTS IV THERMOCOUPLES All temperature controller and high limit functi
7. W gt MOTOR SSS Se ear PICK UP Z A 7N SP t E NEUTRAL Cu LE p S BK 1 RE Missa aca a Sa 2r ow Lan dote 1 5 0 REAR L ee 5 SWITCH D C MOTOR F1 aie PICK UP 9 Q M M AC SP COM 5V 9 i DOOR 5 INTERLOCK 9 SWITCH BR BK 15 OR CONVEYOR SWITCH 3 4 6A BLOWER SWITCH BK 3 4 9 10 COOL DOWN N 0 200 F 82 C 9 PRESSURE o HEAT SWITCH SWITCH 6 So COM 4 3 8 0 id 3 4 i Wie l _ Openesor 343 C 11 CIRCUIT 5 BREAKERS M 3 55661 4 CONTROL s 3 55862 4 3 un SSRC3 p 4 3 SSRC4 2 4 3 5 5 BE 4 ALL HEATERS WIRES 12 3 4 NOTE is 1 ALL WIRES ARE TO BE NO 18 AWG HEATERS UNLESS OTHERWISE SPECIFIED PS200 series electric oven USA version 208 240V main blower motor and heating elements 120V control circuit 208 240V 50 60 Hz 3 Ph 4 pole 5 wire supply 3 hot 1 neutral 1 ground SINVHOVIO ONISIM TVOIH LO3 13 NOLLO3S 691 TRANSFORMER 750 utu PRI 240X480 POWER SEC I DISTRIBUTION NEUTRAL BLOCK 57 Coad Figg A Cuv se com 67 2 Ecl fa i ee es wo 82 1 toe 52
8. aes 43 VII VIII TABLE OF CONTENTS continued High Limit Control Module sssssseme 45 A Part Number Reference High Limit Control Modules 45 B come tase dee 45 C Troubleshooting 45 D Appendice S 46 Instructions for Service Kit 39733 High Limit Conversion Kit for PS300 310 350 8 360 Ovens 5 99 46 Thermocouples 54 A Part Number Reference Thermocouples 54 Thermocouple Functions 54 Troubleshooting 54 D Append eS ettet us 56 Instructions for Service Kits 33984 33985 Oven Thermocouple Kit 11 01 56 Blowers rr CO TH or 68 PS200 series 5 cendi eet en 68 PS360 series OVENS dink eL pere 74 C PS555 570 series ovens 2 76 Blower Motor Centrifugal Safety Switch PS360 series 80 A Part Number Reference Blower Centrifugal Switch 80 ro bleshooting oo eA se hus 80 Burner Blower Motor Centrifugal Safety Switch PS200 series gas PS310 PS314 PS360 PS360WB 55705 80 Air Pressure Safety Switch PS200 series PS555 570 series PS360EWB PS360WB70 81
9. i 1 ally A v 4 D E G This Kit CANNOT be installed in a PS536 oven equipped with the P N 44783 variable pulse electric or P N 44823 PID gas controller shown below 1 o o2 Page 2 of 10 H SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 47321 Digital Temperature Controller Kit 2 02 WARNING BEFORE PERFORMING ANY SERVICE WORK THE ELECTRICAL POWER SUPPLY AND THE GAS SUPPLY MUST BE TURNED OFF Before you Begin 1 This Temperature Controller requires a current version thermocouple for proper operation Check that the thermocouple s installed in the oven match the current three lead flanged versions BE FORE you begin to install the Temperature Controller See Figure 2 If the oven is not equipped with current thermocouples you should replace them BEFORE you install the new Temperature Controller P N 33984 Thermocouple kit for PS300 series PS555 and PS570 P N 33985 Thermocouple kit for PS200 series and PS536 Figure 2 Cable 3 leads Cable 2 leads flange Current thermocouple Obsolete 2 lead X thermocouple clip Installation 1 Checkthe oven s existing temperature controller as shown on the previous page IF TH
10. Middleby technical service manual This Technical Service Manual includes information for the following oven models 5200 220 224 Series e 5310 360 Series 5555 570 Series 2002 Middleby Marshall Inc is a registered trademark of Middleby Marshall inc All rights reserved Ae Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 Marshal Phone 847 741 3300 FAX 847 741 4406 24 Hour Service Hotline 600 238 8444 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 in the industry 772 Middleby 72728 Marshall technical service manual This Technical Service Manual includes information for the following oven models PS200 220 224 Series PS310 360 Series PS555 570 Series P N 47829 Rev C V1 4 02 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 in the industry 2002 Middleby Marshall Inc 2724 Middleby 77248 Marshall is registered trademark of Middleby Marshall Inc rights reserved Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 847 741 3300 F
11. 131 SECTION 3 SERVICING COMPONENTS 5 2 Appendix Instructions for Service 36856 Gas Conversion Kit for PS360EWB WB70 with Midco Burner Natural Gas to Propane 1 98 Remove and retain the aluminum pilot tubing from the burner assembly The end of the tubing that enters the combination gas control valve should be removed first Remove and retain the pilot orifice by unscrewing it counterclockwise from the burner plenum wall Unscrew and retain the pilot tubing connector and the pilot tap plug from the ends of the pilot orifice as shown in Figure 2 When these attachments have been removed discard the pilot orifice Screw the pilot tubing connector and the pilot tap plug into place in the new propane pilot orifice p n 31819 Tighten them to a snug fit Screw the new propane pilot orifice into its opening in the plenum wall Tighten it to a snug fit Ensure that the end of the orifice holding the pilot tubing mount points towards the piping assembly Replace the aluminum pilot tubing that was removed in Step 2 2 above Screw in the brass fittings at both ends of the aluminum pilot tubing Tighten them to a snug fit DO NOT OVERTIGHTEN THE FITTINGS MAIN ORIFICE REPLACEMENT Remove and retain the main orifice holder by unscrewing it counterclockwise from the burner plenum wall Unscrew and discard the main orifice from the inner end of the holder as shown in Figure 3 Screw the new propane main orifice
12. OO OOOOO 9L SL vL EL CL IL OL 6 8 2 1 jenneu 9 8 l OM OMS o 21 Bunsix3 YOUMS 19 OL MONG OL I LHM due uos jeses UO y UBIH UO pIa 01 27 jeuiuJe Jejo nuo2 UMOPjOOD 035012 WHON N3dO Q INSHON WHON NOWWOD NOWWOD 4 66 d L 21329 3 suonoeuuo 9JIM perddng 1 oms YOUMS 19 OL Savia 6 NMOud E L V Y c OO A USAC Bunsix3 A3M JONVHO gt gg 21179913 Jenneu 3LIHM JOJO OL Page 6 of 8 SERVICING COMPONENTS SECTION 3 1 e e e xX 9 gt o o0 c uw o 3 gt 7 1 X
13. SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kits 33984 and 33985 Oven Thermocouple Kit 11 01 PS570 X01 X05 name plate ID numbers and PS570S early with side mounted thermo couples inside or outside the blower motor compartments These ovens are equipped with two thermocouples one on each end wall of the oven The thermocouples may be mounted either inside or outside of the blower motor com partments The thermocouple on the right side of the oven has two leads and sends its signal to the temperature controller The thermocouple on the left side of the oven is a dual function unit It has FOUR LEADS and sends indi vidual signals to the temperature controller and the high limit control module Installing this Kit will replace BOTH thermocouples with current three lead versions located on the back wall of the oven The Kit also requires the installation of a THIRD ther mocouple to act as a high limit sensor Because of this you will need three separate thermocouple kits for these ovens If the oven has already been updated with the rear wall ther mocouple configuration you can simply replace the affected thermocouple Follow the instructions for PS570S late rear wall thermocouples on Page 10 1 If the thermocouples are located outside the blower motor compartments remove and retain the thermo couple covers Remove the end plugs from the oven Then remove 1 or 2 air fingers fr
14. J ite Red Analog Temperature Controller 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 Red White Shielded ground lead High Limit Control Module dE TC TC RESET SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kits 33984 and 33985 Oven Thermocouple Kit 11 01 PS360 Series rear wall thermocouples Figure 3 before 2 96 serial numbers before ASH 0001 Thermeeouple installation PS360 Series Clamp remove Thermocouples on these ovens are located on the rear wall and discard if of the baking chamber They are secured in place by a present Mounting clamp on the outside of the oven tube ded t This Kit eliminates the clamp The flange of the new ther mocouple is held to the back wall of the oven by a retaining plate as shown in Figure 3 n 1 Loosen the retaining clamp and pull the thermocouple eee straight out Disconnect the thermocouple leads Care flange fully thread the wiring out of the oven and discard the thermocouple Remove and discard the cable clamp New Slide the new thermocouple into the mounting tube until thermocouple Retaining the flange is seated firmly on the bac
15. MANIFOLD PRESSURE __ INPUT RATING 175 000 BTU MAXIMUM INLET PRESSURES 14 W C 34 9mbar Stated on the Measured value oven s data plate recorded in Step 8 3 Figure 9 Conversion information label placement PS360EWB placement PS360WB70 placement Page 4 of 4 Jan 98 Rev B p n 36862 138 SECTION 3 SERVICING COMPONENTS Appendix Equivalent Orifice Sizes at High Altitudes Includes 4 reduction for each 1000 ft above sea level 4 02 Orifice Orifice Size Required at Other Elevations Orifice Orifice Size Required at Other Elevations Size at ee EINEN AUS EAE Size at Sea Level 2000 3000 4000 5000 6000 7000 8000 9000 10000 Sea Level 2000 3000 4000 5000 6000 7000 8000 29000 10000 50 50 50 51 51 52 52 52 53 53 53 54 54 55 55 56 56 55 58 59 61 62 62 63 63 001 10 0 f 0 N29 912 012 012 011 139 SECTION 3 SERVICING COMPONENTS ELECTRIC OVEN HEATING SYSTEM PS200 series ovens 1 Description of heating system All PS200 series electric ovens use an on off system for heater activation When the oven demands heat the temperature controller activates contactors that in turn activate the heaters at 100 power The contactors open when the temperature rises to 2 degrees above the set point and close when the oven s temperature falls 2 degrees Fahrenheit below the set point Be cause of residual heat within the oven however the temp
16. PIN LOCATIONS CONNECTS TO FEMALE END OF P N 32142 P N 32482 MALE RCPT PIN LOCATIONS CONNECTS TO FEMALE END S OF P N 44749 B PINS TO P N 31279 MALE RCPT 41 53 42 44 TEMPERATURE CONTROLLER RIBBON CONN CONVEYOR SPEEO DISPLAY FAN LEAD COOLING FAN LEAD ADAPTER BOARD 32482 71 69 71 RIBBON SPLIT BELT ONLY CONVEYOR SPEED DISPLAY PAGE 2 OF2 44 CONV SWITCH 43 4 COM HEAT SWITCH 53 21 67 BLOWER SWITCH 41 REMOTE GROUND PS200R68 series gas oven with modulating valve 208 240V main blower motor and control circuit 208 240V 50 60 Hz 1 Ph 2 pole 3 wire supply 2 hot 1 ground SINVHOVIO ONISIM 0819 NOLLO3S 208V 240V mee For use wilh splil belt convayors only 7 50 60 Hz Thumbwheal Motor Switch Conveyor Spood Control Module Sensor NOTE unspeciflad M M SP Com Count 5V xiv wires are 118 AWG 92129 ep J 8 American Wire Gauge 313 3 2 Conveyor OF Drive x Motor Input Lae Thumbwheal gt 9 9 Blo
17. e is Appendix Instructions for Gas Conversion Kits for Ovens with Wayne Burner Natural Gas to Propane 8 00 5 The pilot pressure should be adjusted as follows The current flow between the pilot hood and the flame sensor when measured with a microamp meter or multimeter holds constant at a minimum of 2 0 uA See Figure 7 The pilot pressure as shown on the manometeris in the range of 8 10 W C 19 9 24 9mbar Adjust the pilot pressure as necessary by turning the pilot adjustment screw on the combination gas control valve Turning the screw clockwise decreases the pilot pressure and currentflow Turning the screw counter clockwise increases the pressure and current flow Some valves may have a burr in the pilot adjustment portal If you have fully tightened the adjustment screw and the manometer still does not register a change in pressure continue to tighten the screw to break through the burr Back the screw out until its top is flush with the top ofits hole then tighten the screw again as necessary to adjust the pressure Repeat this procedure as necessary to properly adjust the pilot pressure If the pilot pressure cannot be properly adjusted switch the oven off and allow it to cool then replace the combination gas control valve Repeat Section VII Gas Leak Test before attempting to adjustthe pilot pressure again After the pilot pressure has been properly adjusted replace the cap
18. 847 741 3300 FAX 847 741 4406 772 Marshall Instructions for Service Kits P Ns 33984 and 33985 Oven Thermocouple Kit This Service Kit provides the parts and instructions necessary to replace one temperature sensing or high limit thermo couple in any of the following Middleby Marshall oven models PS200 Series uses Kit P N 33985 PS536 uses Kit P N 33985 PS570 uses Kit P N 33984 PS360 Series uses Kit P N 33984 PS555 uses Kit P N 33984 These instructions include replacement procedures for ovens built with the current flanged thermocouple AND for ovens built with the obsolete thermocouple without a flange P N 28071 0001 KIT CONTENTS KIT P N 33984 KIT CONTENTS P N 33985 P N Qty Description P N Qty Description 33812 1 Thermocouple type J 6 L 33812 2 1 Thermocouple type J 13 3 8 L B301A8861 Screw hex wshr hd 6 x 3 8 B301A8861 1 Screw hex wshr hd 6 x 3 8 21292 0001 Screw hex wshr hd 10 16 x 3 4 34701 1 Instructions 27276 0001 Cable clamp nylon 41687 Attachment plate PS360 rear thermocouple 34701 Instructions IMPORTANT READ THIS BEFORE YOU BEGIN The thermocouple in your Kit has three leads The red and white leads connect directly to the thermocouple terminals on the oven s temperature controller or high limit control module as appropriate or to a local terminal block that in turn is connected to one of these units The uninsulated lead is a ground wire for the thermocouple
19. H Burner Motor Relay 120V burner blower motors feature a 24V time delay relay located in the electrical junction box on the burner In PS570S ovens the relay is located on the back wall of the machinery compartment Approximately 25 seconds after power is applied to the coil of the relay the contacts will close and complete a circuit to the burner blower allowing the motor to operate This 15 30 second delay is a prepurge for a cold start When the coil of the relay is warm the delay is bypassed Ovens with 208 240V burner blower motors are not equipped with the burner motor relay and do not have a prepurge for a cold start High Flame Solenoid Valve if so equipped Ovens that use an on off gas regulation system are equipped with a high flame solenoid valve The valve is located be tween the combination gas control valve and the burner The valve operates on 110 120V The valve opens when the oven s temperature falls 2 de grees Fahrenheit below the set point and closes when the temperature rises to 2 degrees above the set point Be cause of residual heat within the oven however the tem perature swing after preheating is about 5 degrees Fahren heit above and below the set point The solenoid valve can only be positioned fully open 100 gas flow or fully closed 0 gas flow While the valve is closed gas is still supplied to the burner through the by pass line that goes around the solenoid valve This allo
20. sensor on pilot Replace control board No Yes Correct the 5 sensor Is inlet gas pressure as per problem ceramic cracked manufacturer s specifications Yes No Yes 15 cable grounded out Replace Yes No pilot Correct the problem is sensor or sensor connector shorted out to metal surface No Yes Obtain Replace assembly correct main pressure valve Check for continuity of sensor Correct cable and condition of insulation the problem OK Not OK Connect a microammeter uA Replace in series with GND wire on cable control board Black lead to ground terminal and red lead to free end of ground wire Is DC microamp current 1 5uA or greater with pilot only operation No Yes Check for Replace Proper gas pressure control board Clean pilot assembly Tight mechanical and electrical connections If no improvement is noted it may be necessary to change the orifice size or the complete pilot burner assembly 106 Appendices SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 42810 0117 Pilot Ignitor Kit 7 91 PILOT IGNITOR REPLACEMENT INSTRUCTIONS USING KIT 42810 0117 IMPORTANT When using Kit 42810 0117 the old style pilotignitor bracket must be replaced with the new style bracket contained in the kit or the burner will not light 27363 0002 27170 0264 88210 0067 QTY MM P N 1 1 1 PILOTAGNITOR HOOD AND GROUND STRAP PILOTAGN
21. to 29 50 Min PS570S 27384 0008 22152 0018 22152 0017 Standard PS570SB 70 1350 1 Ratio 15 4 30 Min to 29 50 Min Standard 27384 0011 22152 0024 22152 0017 PS570SB 311 1 Ratio 15T 9T 1 30 Min to 10 Min High Speed 27384 0014 22152 0024 22152 0017 SECTION 3 SERVICING COMPONENTS Appendix Service Bulletin MM 177 Introduction and Compatibility of Conveyor Speed Controller with Digital Display P N 37337 8 00 Bulletin 177 Date 8 18 00 Middleby Cooking Systems Group eterni Toastmaster CTX 1400 Toastmaster Drive Elgin IL 60120 9272 U S A Telephone 847 741 3300 Service and Parts Fax 847 741 4406 yy Middieby Service Bulletin SUBJECT Availability of Conveyor Speed Controller Kits GENERAL Middleby Marshall is changing is standard Conveyor Speed Controller from the familiar thumbwheel control to a unit that features a digital display with pushbutton speed selectors The part numbers of these components are summarized here Speed Controller with Thumbwheel Kit includes control module and thumbwheel 42810 0133 Thumbwheel unit only 42810 0118 Speed Controller with Digital Display Kit includes control module and digital display 37337 Digital selector display unit only 37503 Because of this change supplies of the previous speed controller are VERY LIMITED and the sepa rate thumbwheel is no longer available Immediately stock the
22. veyor speed controller Connect the multimeter s red lead to the SIGNAL terminal then disconnect the motor wires from the ARM and terminals Using a 5 16 open end wrench very slowly rotate the motor pickup shaft while observing the multimeter Two 2 changes from 5VDC to OVDC should occur for each motor revolution Ifthe signal is always at OVDC go to Step 4 Ifthe signal is always at 5VDC OR if the signal changes more than 2 times per revolution replace the pickup assembly Disconnect the pickup signal wire from the speed con troller and check 5VDC at the SIGNAL terminal of the controller f 5VDC is present replace the pickup assembly If OVDC is present replace speed control Figure 19 Connections for pickup test SECTION 3 SERVICING COMPONENTS Conveyor Motor Test Disconnect the gear motor wires from the Speed Con troller terminals ARM and ARM Remove the brush retainer caps from the gear motor DO NOT remove the brushes Set the multimeter to the lowest Ohm scale Then place one meter probe on each brush retaining plate BE SURE THAT NEITHER PROBE TOUCHES THE MOTOR CASING Using a 5 16 open end wrench very slowly rotate the motor pickup shaft while observing the multimeter Dur ing a 1 2 rotation Ohm reading should stay betweeen 3 50 There should NEVER be a complete short There should never be a high Ohm read
23. 90 46454 70 2300 RPM High Altitude Pizza Hut PS570S 60 22230 0087 BK47H 22230 0086 BK55 46745 BX56 1733 RPM Intl Tricon PS570G 60 39587 BK70 39586 80 46453 68 2057 PS555G 50 39587 BK70 42984 BK95H 47044 BX62 2020 RPM 22031 0001 bushing PS555E 50 39587 BK70 39586 BK80 44946 BX61 1680 RPM Domino s 570 60 22230 0087 BK47H 45796 45 46744 BX55 1692 RPM PS570G 60 39587 BK70 47267 65 46452 BX67 1692 RPM PS555G 60 39587 BK70 39910 62 44963 BX58 1580 RPM Papa John s PS555G 60 39587 BK70 39910 62 44963 58 1580 77 SECTION 3 SERVICING COMPONENTS 2 Blower balancing and direction of rotation Proper blower rotation is extremely important Proper blower rotation is shown in Figure 45 Early PS570 blower wheels were positioned so that the open end of the wheel faced into the baking cham ber This was changed on the PS570S and all later models to improve airflow Note that this also means that on early PS570 ovens the counterclockwise wheel is moved to the left side of the oven and the clockwise wheel moved to the right side so that the wheel blades point in the same direction This is reflected in the Part Number Reference information on Page 77 All blower wheels are balanced at the factory Any blower wheel found to be out of balance should be re placed Vibration from an out of balance wheel can cause poor baking and premature bearing failure Note that vibrations ca
24. A 2 4 Ground G Existing Line Capacitors DO REMOVE Figure 1 Rear View of Digital Temperature Controller Showing the Filter Capacitor Assembly Connected to the Terminais HIGH LIMIT CONTROL MODULE On most PS200 series and PS300 series gas ovens the temperature controller monitors the high limit All other oven models use a High Limit Control Module that is inde pendent of the temperature controller Middleby ovens have used several different types of high limit control modules See Figure 23 The United Electric Type 54 control was used for high limit functions only Ovens equipped with this control did not have a cooldown feature The control was used on early PS310 and PS360 electric ovens The United Electric Type 55 control included both high limit and cooldown functions and was used on PS310 and PS360 electric ovens The Watlow high limit control module is the only ver sion still in use by Middleby The module includes high limit functions only The cooldown function is con trolled by the oven s temperature controller except on PS200VL series ovens which do not include a cooldown feature The Watlow high limit control module is used on PS200 series PS360 series and PS555 570 series ovens Service information in this Manual is limited to the current Watlow high limit control module The United Electric units are no longer available Service Kit P N 39733 can b
25. Appendix Instructions to Replace an Alternate Air Switch P N 36194 with Service Kit P N 35624 3 97 p n 36226 Sheet 2 of 2 P 0397 ALTERNATE AIR PRESSURE SWITCH REPLACEMENT INSTRUCTIONS Because the mounting of an Alternate Air Pressure Switch is identical to the blue dial Air Pressure Switch replacing an Alternate Air Pressure Switch with a blue dial Air Pressure Switch part of Service Kit p n 35624 requires removing the mounting hardware of the inoperative alternate Air Pressure Switch and using this mounting hardware in the same holes of the bracket panel installing a blue dial Air Switch in the same location Observe the tube on the inoperative Air Switch to which the flexible plastic tubing is attached and install this tubing on the matching short tube of the new Air Switch Electrically however slight differences affect this replacement A different type of termination on the Alternate Air Pressure Switch requires a change in the termination of the orange wires leading to a replacement blue dial Air Pressure Switch Install the replacement Air Pressure Switch as follows 1 Remove the cover of the inoperative Air Pressure Switch 2 Label each orange wire with the terminal number or symbol 2 identifying its terminal on the old Air Switch The new Air Switch uses an identical set of identifying symbols and numbers Pull the spade lug easy on term
26. Replace control board Operate system several complete heat cycles 104 SECTION 3 SERVICING COMPONENTS SPARK IS PRESENT PILOT WILL NOT LIGHT Are pilot connections CORRECT START and securely fastened Is 3Vac fused control board or 25Vac non fused control No Yes board present across terminalsTH TR and TR Connect Yes No Securely 1g 5 manual gas cock terminals knob ON Replace control Y Yes board Turn ON gas cock Is inlet pressure as per manufacturer s specifications No Yes 15 gas present at pilot burner Obtain correct pressure CAUTION Do not use match to test for gas presence Yes No Make sure pilot line is not kinked or obstructed Check for clean orifice If okay replace valve assembly Check for drafts shield as necessary check for clean orifice 5 spark gap 1 8 and located in pilot gas stream Correct or replace pilot burner assembly 105 SECTION 3 SERVICING COMPONENTS PILOT LIGHTS MAIN VALVE WILL NOT COME ON Does spark stay on for more than 60 seconds after pilot has proven START Make sure ignitor sensor cable is not wrapped around any pipe or accessories No Is 12Vac fused control board 25Vac Yes 15 ignitor sensor cable securely attached to non fused control board between terminals TH and TR on main valve ignitor sensor terminal No Yes oncontrol board and ignitor
27. Dungs square case air switch with dial adjustment Replace with same Adjustment dial in W C or mbar Positive pressure Negative pressure Yamatake Honeywell air switch non adjustable Replace with same Adjustment screw fixed at proper setting cannot be adjusted Positive pressure Negative pressure SECTION 3 SERVICING COMPONENTS 1 negative pressure side of air switch Original style round air switch with screw adjustment P N 28023 0005 This was the standard switch used through 9 96 and is no longer available If it must be replaced use Kit P N 35624 for use in the USA or 35625 for export use See 2 below for a description of these kits Dungs square case air switch with dial adjustment This was the standard switch used from 9 96 through 1 02 It cannot be upgraded to the current Yamatake Honeywell octagonal switch and so should still be used as a service replacement EXCEPTION PS570G and all P8555 ovens have used the Yamatake Honeywell switch throughout their production run see 4 below Two different models were used one for domestic ov ens and another for export ovens The switches are identical except for the markings on the dial The do mestic unit measures pressure in water column inches in W C while the export unit measures pressure in millibars mbar Domestic switch Kit P N 35624 e Export switch Kit P N 35625 Dungs square case alternate air
28. O Gas Conversion Kits Ovens can be converted from natural gas to propane opera tion or from propane to natural gas operation by the instal lation of the appropriate Gas Conversion Kit Refer to Part Number Reference Gas Orifices and Gas Conversion Kits on Page 91 for a listing of kit part numbers 2 Converting the oven to operate on a different gas type gen erally requires Replacement of the regulator spring on the combina tion gas control valve The spring is located under neath the pressure regulator screw Note that on PS360EWB and PS360WB70 ovens equipped with the Midco burner replacement of the regulator spring is not necessary Replacement of the main orifice pilot orifice and by pass orifice Note that ovens equipped with the modu lating gas system do not use a bypass orifice e Adjustment of the main and pilot gas pressures 3 Documenting the gas conversion using the labels and tags supplied in the kit Instructions for the gas conversion kits are provided in the Appendices section t 4 100 P Burner and Gas Train Troubleshooting 1 Burner Blower Motor If there is 110V or 208 240V as appropriate to the motor terminals it should be running If the motor is not running replace it Burner Blower Motor Centrifugal Switch or air pressure safety switch If the burner blower motor is running at top speed and you cannot measure 24V across the supply terminals of the ignition module t
29. conductor t ribbon cable 52 CN E E Switch D E 5 1 4 mE E Blower Switch 7 51 1 Co Heat iud 10 Coll Fan Motor Switch Cooldown TC brn Alc 2 wht o J1 2 s 180 kac i Limi 3 2 brn Valve a MV Terminals 650 F 343 C purple Relay Coll Gpit 12 2 f ii a m 24V 1555 1 1 4 2 115V e cdd a 34 14 Burner ae voe 149 n wht ignition Ignitor Pilot ah Oya NH 42 22 42 23 E m Module J Gnd 7 Centrifugal Ac 1 Spark 16 gt lt Hun E To Gas Control 177 J1 High Flame Pilot Outlet tic Solenoid Valve wht PS200R68 series gas oven with solenoid valve 208 240V main blower motor 120V control circuit 208 240V 50 60 Hz 1 Ph 3 pole 4 wire supply 2 hot 1 neutral 1 ground SINVHOVIO ONISIM 0819 NOLLO3S 99 1 PANEL GROUND SIGNAL gaat AMPLIFI PRIMARY 240V 50 60 Hz SECONDARY 24V 25 IER 0 20 i 1 61 SHROUD NO 2 2 INPUT 4 20 OUTPUT 24vAC INPUT REAR AIR SWITCH 1 SENSOR FRONT AIR SWITCH 2 37 39 57 59 PILOT LINE PILOT nm E 59 56 XFMR2 PRIMARY 240v 50 60 Hz SECONDARY 24V 65 UNE IGNITION VALVE MODULE
30. 1 47322 Instructions TABLE OF CONTENTS Controller Types Before You Begin Installation Electrical Connections Jumper Setting Programming Diagnostic Error Messages Operating Instructions be left with customer after installation Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 847 741 3300 FAX 847 741 4406 Middleby Corporation Service Hotline 1 800 238 8444 2002 Middleby Marshall 47322 Rev V2 2 02 1 of 10 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 47321 Digital Temperature Controller Kit 2 02 Controller Types This Kit includes one Digital Temperature Controller P N 46837 that can operate at 120 240V and can be programmed to operate in on off PID or variable pulse modes The Controller is shown in Figure 1G below By following these instructions the Controller can be installed into any Middleby Marshall oven equipped with the following Controllers P N 28071 0012 Fig 1A Analog Temperature Controller without high limit and cooldown functions operating at 120V on off mode only P N 28071 0018 Fig 1A Analog Temperature Controller with high limit and cooldown functions operating at 120V on off mode only P N 34983 Fig 1B Analog Temperature Controller without high limit and cooldown functions operating at 120V on off mode only Used on PS200VL models As of 12 01 P N 34983 is still available an
31. 18 AWG UNLESS OTHERWISE SPECIFIED FOR USE IN SPLIT BELT APPLICATIONS ONLY PICK UP D C CONTROL Dc Y E IGROUND 10 AMP 0 O O v 16 WIRE d BLACK FR CONTROL HSG NA CIRC BRKR i SAFETY SWITCH d 10 d CIRC GRIEF in 10 AMP CIRCUIT BREAKER 42 Leal E d 6 GA WIRE oy XEMR CONVEYOR 4 x 230 115V SWITCH 3 x BLUE gt 5 2 BLOWER SW MOTOR MOTOR BLACK 4 MICRO Sw BROWN Q O Q RED BLK BRN RED PURPLE ee Spoj 9 ses COOLING FAN LEFT start PURPLE START 9 COOLING FAN RIGHT BLACH BLACK BMITER COOLDOWN BRN RED Cy CONTACTOR COIL ORANGE BLACK Ss stue O ORANGE 4 3 BRN 82 O gt FERMNAES HIGH TEMP Limit CONTROLLER WHITE N 0 650 F4343 O ORN 11 12 PURPLE BLUE w WHT PUR w WHITE CONTROLLER TC YELLOW 13 m 0 20ma gt 2 1 GRN pA PRESSURE SPARK input _ 5 oo oor Sy PILOT u 0 24 gt 153219 GRO RED 5 BURNER J o ae BURNER BLOWER ITION IGNITOR D 2 MODULE SENSOR PILOT POTER tP BURNER 4 5 GAS SRD 5 CONTROL PILOT 9 U OUTLET gt t BLUE RED ORANGE w WHITE ORANGE PS360EWB gas oven with Wayne burner and temp control 36056 or 46837 20
32. 240V 4500W 12 80 Parallel 380V 4500 3220 Parallel 416V 3380W 12 80 Series 480V 4500W 12 80 Series Checking the Heating Elements The most common problems encountered with electric heaters are Open or bad connections Open shorted or grounded heating elements To troubleshoot the heating elements disconnect all leads at the back wall and check each element with a digital multimeter set to Ohms Q Correct ratings are shown in the table in the preceding section Zero read ing on the ohm scale indicates an open or shorted ele ment Figure 78 Fan shroud removed 141 SECTION 3 SERVICING COMPONENTS It is also possible to check for an open element using an ampmeter Any current through the element indi cates that the element is not open Changing Heating Elements NOTE Wires going from the mercury contactor or solid state relays as appropriate to the heating ele ments are rated at 12 gauge TAGT 482 F 250 C DO NOT under any circumstances use a wire of lesser rating or quality NOTE lugs and connections are rated at 600 F 316 C All heating element connections are double nutted To remove the element Remove the blower belt e Remove the 12 electrical lead connections to the heaters at the back wall Remove the 12 bolts that hold the rear oven panel to the body Once removed DO NOT lay the panel on either its front or back side This can damage the heating elements a
33. Bundle the loose wires together and allow them to hang loose for later reconnection Remove the mounting screws that hold the United Electric high limit control in place Then remove and discard the high limit control and its mounting screws Position the new high limit control in place on the left wall of the control compartment as shown in Figure 3 When positioning the control Ensure that the control is positioned AT LEAST 1 25mm back into the compartment to allow the compartment door to close Ensure that additional space is left underneath the control for the reset switch NOTE Instead of holding the high limit control in place you may use the dimensions provided in Figure 4 to determine the location of the control and its mounting holes Mark the locations of the two mounting holes for the high limit control Then drill the holes using a 3 16 drill bit Secure the high limit control in place using the kit supplied 6 32 x 1 5 8 screws and 6 32 nuts Position the bracket for the reset switch on the left wall of the control compartment as shown in Figure 3 Note that the face of the bracket with the large circular switch mounting hole should face YOU Also the bracket should be positioned AT LEAST 3 75mm back into the compartment to allow the door to close While holding the bracket in place mark the locations of the two mounting holes Then remove the bracket and drill the holes using a 3 16 drill bi
34. Carefully adjust the screw until its top is flush with the top of the regulator Turn the adjustment screw six complete turns in a clockwise direction This preliminary pressure setting is approximately 3 1 2 W C 8 7mbar Install the silver kit supplied cap screw BYPASS ORIFICE CONVERSION NOTE Ovens are equipped with EITHER an on offsolenoid valve with a separate bypass line OR with a modulating gas valve Referto the illustrations on Page 2 When installing this Kit the bypass orifice will only be changed if the oven is equipped with a solenoid valve Ifthe oven is equipped with a modulating gas valve skip ahead to Section IV Pilot Orifice Conversion Ifthe ovenis equipped with a solenoid valve continue on to Step 1 below Unscrew the compression nuts at both ends of the bypass tube and slide them back and out of the way Then remove and retain the tubing See Figure 3 Remove and discard the existing bypass orifice Slip the kit supplied bypass orifice into the discharge end of the bypass tube as shown in Figure 3 With the orifice in place push the tube back into the compression fittings until it bottoms While holding the tube in place slide the compression nuts into place Tighten them to a snug fit with your fingers Gently tighten the nuts one complete turn with a wrench DONOTOVERTIGHTEN THECOMPRESSION NUTS 127 Figure 1 55705 gas train with solenoid valve shown Refer to the illustrat
35. Switches Front Control Door Safety Switch gt Right Rear Safety Switches blk Pressure Switch Heat QNO Switch orn High Limit 650 F 343 C 15 16 o Temperature 7 3 Controller qo 75 zs Se wht High Flame Solenoid Valve D C Motor D C Control 58 lt 9 2 Q Conveyor Switch wht Te Blower Switch 10 High Limit brn wht Control HLC 2 3 cooling Fan Left am M An ooling Fan Right Cooldown TC brn wht Coil Blower Motor 180 F 82 C blu Lo Pilot Burne Pilot Ignitor Burner js Centrifugal Sensor Grd T T d Switch To GasControl wht Pilot Outlet SN3AO 531435 029 9995 SINVHOVIO ONISIM 0819 NOLLO3S 5570 or PS570S gas oven with solenoid valve and analog temp control 208 240 main blower motor 120V control circuit 208 240V 50 60 Hz 1 Ph 3 pole 4 wire supply 2 hot 1 neutral 1 ground NOTE ALL WIRES ARE TO WHITE BE 18 AWG UNLESS OTHERWISE SPECIFIED FOR USE IN SPLIT BELT APPLICATIONS ONLY MOTOR SPEEO Hz _ jg SEEN i noun conveyor CONVEYOR SPEED CONTROLMODULE SENSOR WHITE DRINE MOTOR SP COM SIG 5 75 mi BLACK BLACK RED pu REAR lo SAFETY TCHES 15 Swi LEFT
36. This control also continuously monitors the cycles and adjusts itself accordingly If an unstable frequency utility is common to the area it is recommended to use the PN 31020 control Ali DIP switch Conveyor Speed Controls provide a variable DC voltage output determined by the thumbwheel setting and the frequency input from the speed control pick up assembly DIP switch control PN 28074 0018 REV B and DIP switch contro PN 31020 contain the program settings for all Middleby Marshall Ovens that use digital conveyor controis Both controls have built in diagnostics to assist the service technician SECTION 3 SERVICING COMPONENTS Appendix Service Bulletin 133 Installation Instructions for Conveyor Speed Controller Kit with Thumbwheel P N 42810 0133 4 95 Features Continued 5 Both controls are protected against gear motor shorts 6 Both controis have meta housing covers that guard against handling damage and minimizes radio frequency interference RFI Note Contro PN 28074 0018 REVISION B contains all current DIP switch settings currently used in the field Prior to REV B this contro was not compatible with the 570 Series conveyor chain driven ovens The revision letter is printed on the controls label should you be concemed if your inventory is not updated Compatibility Both the above referenced controis are compatible with all current and previous Middleby Marshall digital conveyor controls gear motors
37. late 208 240V and 480V UL versions ONLY For these ovens the kit replaces the Type 55 con trol with the Watlow high limit control and uses the oven s temperature controller to provide the cooldown circuit Page 1 of 8 Qty P N 2ft 610mm 27152 0050 2ft 610mm 27152 0053 2ft 610mm 27152 0054 8 1455A8750 1 3002693 2 2000076 2 1421B8803 4 2001327 Description Wire 18 AWG brown Wire 18 AWG white Wire 18 AWG purple Wire connector 1 4 6 4mm Wire tie nylon Screw 6 32 X 1 5 8 Screw 6 32 X 1 4 Nut 6 32 Figure 1 United Electric Type 54 High Limit Control United Electric Type 55 High Limit Cooldown Control Lighted Reset Switch Watlow High Limit Control P N 39732 Rev V1 5 99 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 39733 High Limit Conversion Kit for PS300 310 350 amp 360 Ovens 5 99 B INSTALLATION WARNING BEFORE PERFORMING ANY SERVICE WORK THE GAS SUPPLY IF SO EQUIPPED AND THE ELECTRICAL SUPPLY TO THE OVEN MUST BE TURNED OFF Open the machinery compartment and control compartment access panels Locate the high limit thermo bulb capillary assembly Its location is shown in Figure 2 Loosen the set screw that holds the assembly in place Remove the thermo bulb capillary assembly from the mount ing tube Disconnect the wires 2 for the Type 54 control 4 for the Type 55 control from the terminals of the United Electric control
38. pulse output electric ovens with variable pulse system Neither of these systems were available with ovens equipped with these controllers lt Terminal for 28071 0012 and Terminal for Terminal for Description 28071 0018 34983 46837 1 TC 8 TC 2 TC 7 TC 5 COM 5 Input to Temperature Control Relay 6 NO 4 Output to High Flame Solenoid or Heater Contactors L2 L2 L2 Neutral L1 L1 Power G Ground 13 9 Input to Cooldown Relay 14 10 Output from Cooldown Relay 15 11 Input to High Limit Relay 12 Output from High Limit Relay 15 PID or Variable Pulse Output 16 PID or Variable Pulse Output Figure 5a Figure 5b Modulated Gas Output System Variable Pulse Output System Modulating Amplifier board valve 4OL O 20VDC pulsed output 05 30 1 0 24VDC output Az 4 20MA input Relay NOTE Safety switches NOTE Controller P N 32571 used Terminals 4 amp 5 may be placed between for the 4 20mA input to the amplifier board 24VAC the temperature controller These connections must be moved to Terminals input and the relay on some 15 amp 16 on the new controller as shown oven models Page 5 of 10 1 2 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 47321 Digit
39. ves 0 06804 atmospheres 5 horsepower Watts pounds sq in feet of water centimeters inches pounds sq in in of mercury h boile BTU h centimeters feet orsepower boiler ELE pounds sq in inches of water centimeters meters horsepower boiler kilowatts temp 0 273 absolute temp K centimeters millimeters i temp C 17 78 F cm of mercury atmospheres Orsepowernours temp F 460 absolute temp cm of mercury ft of water inches centimeters temp F lemperature cm of mercury kg sq meter inches millimeters therm BTU cm of mercury bs sq ft inches meters DON MIU ph cm of mercury bs sq in psi inches feet cubic feet cubic inches of mercury atmospheres dade cubic feet cubic inches inches of mercury feet of water cubic feet cubic meters inches of mercury inches of water wa BTU cubic feet cubic yards inches of mercury bs sq ft Wal BTU mi cubic feet gallons U S inches of mercury bs sq in psi wa oot pounds sec cubic ft min cubic cm sec inches of water atmospheres Wa bola cubic ft min gallons sec dat 1 in 3 kilowatts cubic ft water b 60 F 16 C Mos dd aos ido CONT inches of water bs sq ft Wa 4 inches of water bs sq in psi w
40. 0010 22176 0016 22176 0004 22176 0014 31821 22176 0014 43059 22176 0014 MAIN ORIFICE NATURAL 0 2047 5 18mm 0 18274 62 0 2197 5 56mm 0 2507 6 35mm 0 2347 5 94mm 0 25076 35 0 228 5 79mm 0 25076 35mm GAS 22174 0011 22174 0011 22174 0011 22174 0011 31818 22174 0011 22174 0011 22174 0011 PILOT ORIFICE NATU 0 02870 71 0 02870 71 0 02870 71 0 02870 71 0 03270 81 0 02870 71 0 02870 71 0 028 0 71 RAL GAS 22174 0006 22174 0006 22174 0006 22174 0006 22174 0006 22174 0006 NONE 22174 0006 BYPASS ORIFICE NATU 0 060 1 52 0 0607 1 52 0 060 1 52 _0 06071 52 0 060 152 0 0607 1 52 0 0607 1 52mm RAL GAS 53 drill 53 drill 53 drill 53 drill 53 drill 53 drill 53 drill 28092 0019 28092 0019 28092 0019 28092 0019 28092 0019 28092 0019 28092 0019 28092 0019 GAS VALVE SPRING KIT NATURAL GAS 42810 0122 42810 0123 42810 0119 42810 0124 36856 44665 43062 42810 0124 GAS CONVERSION KIT NATURAL TO PROPANE 22176 0007 22176 0017 22176 0003 22176 0015 31822 31980 43060 22176 0015 MAIN ORIFICE PROPANE 0 1285 3 26mm 0 11372 87 0 1347 3 40mm 0 152 3 86mm 0 185 4 70mm 0 165 4 19mm 0 141 3 58m m 0 152 3 86mm 22174 0010 22174 0010 22174 0010 22174 0010 31819 22174 0010 22174 0010 22174 0010 PILOTORIFICE PROPANE 0 018 0 45mm 0 018 0 45mm 0 018 0 45mm 0 018 0 45mm 0 02570 64 0 01870 45 0 01870 45 0 01870 45 22174 0009 22174 0009 22174 0009 22174 0
41. 10 11 Component Checks Reset System After Lockout If the oven enters safety lockout the system must be reset before attempting further operation or checkout The system will remain in safety lockout until it is re set Shut system OFF Turn Heat switch OFF Wait at least five minutes then turn Heat switch ON Check Spark Ignition Circuit The electronic module and step up transformer in the ignition module provide spark ignition at 15 000V open circuit This circuit can be checked at the ignition module as follows a Turn OFF the gas flow at the manual shutoff valve b Disconnect the ignition cable at the ignition mod ule terminal to isolate the circuit from the pilot burner ignitor Sensor and prepare a short jumper lead using heavily insulated wire such as a spare ignition cable c Energizethe ignition module and touch one end of the jumper firmly to the control board ground termi nal GND Do not disconnect the existing ground lead Move the free end slowly toward the stud terminal to establish a spark and then pull the lead wire slowly away from the stud Note the length of the gap at which arcing stops d An arc length of 1 8 3 2mm or more indicates satisfactory voltage output Replace the ignition module if no arc can be established or if the maxi mum gap is less than 1 8 3 2mm and power to the ignition module input terminals was correct WARNING Do Not touch either stripped end of jumper or
42. 11 Position fan blade flush with 5 8 shoulder on shaft as called out in Figure 34 NOTE Fan blade hub has a 1 2 bore The fan shaft is turned down from 5 8 to 1 2 to receive fan blade 12 Apply High Temperature Loctite Type RC 620 to fan blade set screws NOTE Tighten the two set screws on fan blade per the following sequence when viewing fan blade from front first the screw at the 12 00 position then the screw at the 3 00 position 13 Recheck fan shaft rotation before installing back wall to oven cavity Be sure fan assembly has ad equate clearance inside orifice ring and is not rub bing NOTE Apply anti seize compound MM P N 17110 0017 to all 12 bolts before installing back wall assem bly to oven 14 Install back wall on oven 15 Check motor pulley and fan pulley alignment See Figure 33 16 Install fan belt NOTE Excessive fan belt tension will create overload ing of rear bracket fan shaft bearing Refer to Blower Belt Tension on Page 69 Figure 33 Four point alignment test for correct pulley alignment Cord tied to shaft Cord must touch sheaves at four points indicated by arrows 72 SECTION 3 SERVICING COMPONENTS Figure 34 Bearing replacement and alignment current style PS200 fan shaft assembly Shoulder Bearing Set Screws Item Qty Part Number _ Description Item Qty Part Number Description 1 1 37900 00
43. 2 02 28 Bix Ball Times tat Dette 12 e Service Bulletin MM 189 New Conveyor Gear Time of Delivery TOD nt cot 12 Motors Brushes and Pickup Clamps 8 01 29 DIP switch settings for Conveyor Speed Controller Section 3 Troubleshooting and Servicing Components play P N 59 Conveyor Speed Controller and Drive 13 Temperature Controller 30 A Part Number Reference Speed Controllers 13 Tos leat Number References Temperature Controllers is 91 B Part Number Reference Pickup Assemblies 14 B Description AREE TE 32 C Preparing to Service the Speed Controller 14 C High Limit Cooldown 5 32 D Controller Motor Failure 15 D Troubleshooting T OO Basic Troubleshooting Flowcharts 16 32 If the Conveyor RUNS at Full Speed 16 A S 32 If the Conveyor Will Not 17 Instructions for Service Kit 47321 Digital Temperature Controller Kit 2 02 33 Service Bulletin 136 Electrical Noise Filter Capacitor Assembly on Temperature Controllers te C bos Nee
44. 27 70 2 03 68 7 1 00 16 0 7 00 0 515 17 4 0 253 4 04 174 Pressure conversion chart To use this chart simply place a straightedge so that it intersects the known value and lies across the center of the bullseye Readings on all scales will then be equivalent Ohm s Law equation wheel Using this wheel you can calculate any one of the following four basic factors of electricity as long as two of the others are known Power Watts W shown as W Current Amperes A shown as e Voltage Volts V shown as Resistance Ohms 0 shown as R Choose an equation that will give you the value that you need based on what values are already known SECTION 5 REFERENCE 5 0 5 5 2 5 2 0 ounces sq in inches of water 1 inches of mercury 10 un on 175 SECTION 5 REFERENCE Common electrical wiring diagram symbols SWITCHES LIMIT DISCONNECT CIRCUIT See INTERRUPTER BREAKER HELD HELD CLOSED OPEN LIMIT CONTINUED LIQUID LEVEL VACUUM amp PRESSURE TEMPERATURE PROXIMITY SWITCH NORMALLY NORMALLY NORMALLY NORMALLY crose open OPEN CLOSED OPEN CLOSED FLOWI AIR WATER ETC FOOT TOGGLE CABLE PLUGGING NON PLUG NORMALLY NORMALLY NORMALLY NORMALLY OPERATED OPEN CLOSED OPEN CLOSED EMERG F SWITCH PLUGGING SELECTOR ROTARY SELECTOR W LOCK OUT 2 POSI
45. 27 PRESSURE REGULATOR FIRST AUTOMATIC VALVE SOLENOID OPERATOR VALVE DISC OUTLET FIRST AUTOMATIC VALVE SECOND AUTOMATIC ned VALVE DIAPHRAGM NOTE SECOND AUTOMATIC VALVE OPERATOR AND SERVO PRESSURE REGULATOR SHOWN OUTSIDE GAS CONTROL FOR EASE IN TRACING GAS FLOW A SLOW OPENING GAS CONTROL HAS A GAS FLOW RESTRICTOR IN THIS PASSAGE 118 SECTION 3 SERVICING COMPONENTS Appendix Instructions for All Gas Conversion Kits for Ovens with Wayne Burner Natural Gas to Propane 8 00 o Middleby 2728 Marshall Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 USA 847 741 3300 FAX 847 741 4406 Instructions for Service Kits 42810 0119 42810 0122 42810 0123 42810 0124 43062 44665 Gas Conversion Kit for Middleby Marshall Ovens Natural Gas to Propane Operation KIT COMPONENTS 25200 PS220 224 PS310 360 PS360WB___ PS360WB70 EWB 25555 PS570S Description 1 42810 0122 42810 0123 42810 0119 42810 0124 44665 43062 42810 0124 GAS CONVERSION NATURAL TO PROPANE 1 22176 0007 22176 0017 22176 0003 22176 0015 31980 43060 22176 0015 ORIFICE MAIN 0 1285 3 26mm 0 113 2 87mm 0 134 3 40 0 152 3 86mm 0 165 4 19mm 0 141 3 58mm 0 152 3 86mm 1 22174 0010 ORIFICE PILOT 0 018 0 45mm 1 22174 0009 22174 0009 22174 0009 22174 0009 22174 0009 NONE 22174 0009 ORIFICE BYPASS HIGH FLAME 0 038 0 97mm 0 038 0 97 mm 0 038 0 97mm 0 038 0 97mm 0 038 0
46. 5 minutes and then turned ON again For ovens with an On Off gas regulation sys tem with solenoid valve Temperature Controller terminals 4 amp 5 power for the primary relay contacts for the high flame solenoid valve For PS360EWB ovens with a modulating gas system and Temperature Controller P N 32571 Temperature Controller terminals 4 amp 5 input signal to amplifier board For all other ovens with a modulating gas sys tem Temperature Controller terminals 15 amp 16 input signal to amplifier board In all ovens the temperature sensing thermocouple s send a millivolt signal to the temperature controller As long as the temperature inside the oven is below the set point of the Temperature Controller the Controller will do the following 1 Forovens with an On Off gas regulation system If the temperature sensed by the thermocouple s is below the set point on the Temperature Controller the Controller energizes the high flame solenoid When the solenoid is energized the solenoid valve permits 10096 gas flow Power to the solenoid is cut when the temperature reaches the set point which closes the valve This permits on off gas flow to the burner When power is cut to the high flame solenoid the burner will remain ON in the low flame mode When the temperature drops a few degrees the Tempera ture Controller will again energize the high flame solenoid which opens the valve and restores gas flow to 10096
47. 606 25 004 25 400 DRILL SIZE DIAMETER SECTION 5 REFERENCE General conversion factors MULTIPLY BY TO OBTAIN MULTIPLY BY TO OBTAIN MULTIPLY BY TO OBTAIN atmospheres 44 0 5080 cm sec meters centimeters T60mm of mercury ft sec meters millimeters at 32 0 14 696 lbs sq inch km hr meters atmospheres 16 0 of mercury meters min meters inches atmospheres in of mercury miles hr mph meters yards t ji water BTU ounces fluid cubic inches atmospheres g sq cm atmospheres bs sq inch galons U S eo acu PEN atmospheres 1 058 tons sq ft gallons imp ounces sq in bs sq in psi BTU British 00520 ROUEN U ounces sq in inches of water fae 2520 g 0 iter BTU 7775 t bs gallons U S Cubic inches ounces Th 0000 Ad allons U fluid ounces E liters pounds of water cubic ft ae pounds of water cubic in t bs sec bs 0 060 16 pounds of water gallons pounds sq ft 0 01602 feet of water mg Wat 5 pounds sq ft 0 006945 lbs sq in psi ERI horsepower _kilowatts pounds sq in
48. A Part Number Reference Air Switches 81 B cde edere 82 Appendices cse eeepc 83 Instructions for Service Kits 35624 and 35625 Air Pressure Switch Replacement Kits 1 97 83 Instructions to Replace an Alternate Air Switch P N 36194 with Service Kit P N 35624 3 97 85 570 570 Flame 87 A Part Number Reference Flame Gate 87 B Flame Gate 87 Gas Train and Burner System 88 A Part Number Reference Gas Train Components 88 B Part Number Reference Gas Orifices and Gas Conversion Kits C Component Identification D Pilot Ignitor Assembly E Burner Blower Motor sss Air Sh tterz 95 G Burner Transformer needed 96 H Burner Motor Relay 96 High Flame Solenoid Valve 96 J Bypass Low Flame Orifice 96 Modulating Gas 97 E Amplifier aure SB 97 M Combination Ga
49. An indicator on the Temperature Controller will show whether the high flame solenoid is energized or whether the burner is activated which is effec tively the same This indicator varies by Tempera ture Controller model Referto the instructions for the appropriate Temperature Controller for an illus tration and description of this indicator 2 For ovens with a modulating gas system In re sponse to the signal from the thermocouple s the Temperature Controller sends a 4 20mA signal to the amplifier board The amplifier board converts this to a 0 20VDC signal which is sent to the modu lating gas valve The valve opens or closes in pro portion to the signal from the amplifier board al lowing the gas flow to be regulated as required from 0 100956 An indicator on the Temperature Controller will show whether the burner is activated This indica tor varies by Temperature Controller model Refer to the instructions for the appropriate Temperature Controller for an illustration and description of this indicator SECTION 1 SEQUENCE OF OPERATION F High Limit NOTE Most PS200 Series and PS360 series gas ov ens use the high limit feature of the Temperature Con troller All other oven models use a separate High Limit Control Module Refer to the wiring diagram for the appropriate oven model to check whether a separate High Limit Control Module is used The high limit relay will shut the oven burner OFF 1 Ifthe high limit
50. Before proceeding to Step 6 it is advisable to position the rear wall assembly in an upright vertical position using a block of wood under the fan ring 6 When installing the drive bracket Item 5 insert one 3 8 flat washer Item 4 at the four outer holes and one 3 8 special flat washer Item 12 at the 4 inner holes between the bracket and back wall at the mounting locations Use eight 3 8 16 X 1 screws Item 2 and assemble a 3 8 lockwasher Item 3 and a 3 8 flat washer Item 4 into each screw Insert a screw at all 8 locations Hand tighten only at this time 7 Insert fan shaft alignment tool 13 as shown into back wall NOTE The bracket assembly is designed for slight up and down and right to left movement to attain free shaft rotation when the shaft alignment tool is in place Once free shaft rotation is achieved tighten all eight bracket screws Item 2 8 Tighten rear pillow block bearing screws Item 9 then front pillow block bearing screws 9 Remove shaft alignment tool then recheck fan shaft for free rotation 10 Install pulley 7 on fan shaft and position fan shaft per dimension shown in Figure 34 Align the flats machined on fan shaft with the bearing set screw holes Apply High Temperature Loctite type RC 620 on bearing set screws and then tighten set screws Recheck fan shaft for free rotation 11 Apply anti seize compound on fan shaft before in stalling fan blade Item
51. Conversion Kits for Ovens with Wayne Burner Propane to Natural Gas 8 00 o Middleby 2728 Marshall Instructions for Service Kits 42810 0120 42810 0125 42810 0126 42810 0127 43061 44664 Gas Conversion Kit for Middleby Marshall Ovens Propane to Natural Gas Operation KIT COMPONENTS 1 42810 0125 42810 0126 42810 0120 42810 0127 44664 43061 42810 0127 KIT GAS CONVERSION PROPANE PS200 PS220 224 PS310 360 PS360WB PS360WB70 EWB 5555 PS570S Description TO NATURAL 1 22176 0010 22176 0016 22176 0004 22176 0014 22176 0014 43059 22176 0014 ORIFICE MAIN 0 204 5 18mm 0 182 4 62mm 0 219 5 56 0 250 6 35mm 0 250 6 35mm 0 228 5 79mm 0 250 6 35mm 1 22174 0011 ORIFICE PILOT 0 028 0 71mm 1 22174 0006 22174 0006 22174 0006 22174 0006 22174 0006 NONE 22174 0006 ORIFICE BYPASS HIGH FLAME 0 060 1 52mm 0 060 1 52mm 0 060 1 52mm 0 060 1 52mm 0 060 1 52mm 0 060 1 52mm 53 drill 53 drill 53 drill 53 drill 53 drill 53 drill 28092 0019 KIT GAS CONTROL VALVE SPRING NATURAL GAS ENGLISH page 1 LABEL NATURAL GAS YELLOW GREEN 22500 0123 LABEL GAS CONVERSION 22501 0007 TAG GAS CONTROL CONVERSION 88210 0070 INSTRUCTIONS 7 NOTE The bypass orifice is not used if the oven is equipped with a modulating gas These ovens include For additional information refer to Part of these instructions Bypass Orifice Conversion PS360EWB all
52. Conveyor Speed Controller Kit for PS200R68 series ovens KIT COMPONENTS Qty P N Description 1 37337 Conveyor speed controller with digital display 1 44749 Cable assembly PS200R68 series ovens 1 44757 Instructions PS200R68 series oven conveyor speed controller kit This Service Kit will update one Middleby Marshall PS200R68 PS220R68 or PS224R68 oven to operate using the current digital conveyor speed controller with keypad display P N 37337 instead of the previous controller with thumbwheel adjustment P N 42810 0133 If the oven is already equipped with controller P N 37337 this Kit is not necessary P N 37337 may be used as a direct replacement for the existing controller WARNING BEFORE PERFORMING ANY SERVICE WORK THE ELECTRICAL POWER SUPPLY AND THE GAS SUPPLY MUST BE TURNED OFF Disconnect the oven from its electrical power supply at shown on the case of the controller and are also provided the circuit breaker fused disconnect For gas ovens in Figure 1 shut off the gas supply to the oven 3 Install the new module place Close and fasten the Identify the 24 pin control cable female at both ends that machinery compartment door connects the rear of the remote box on top of the oven to the rear of the machinery compartment on the side of the oven Temporarily remove the remote box from the top of the oven Open the remote box Disconnect the thumbwheel unit s ribbon cable plug from its socket on the
53. Figure 2 Pilot orifice assembly Pilot tubing connector Pilot tap plug Pilot orifice Figure 3 Main orifice and holder Main orifice Qo holder Main orifice Main manifold tap plug leave in place Figure 4 Low flame orifice replacement Aluminum Low flame orifice Solenoid valve with a solution of soap and water 2 3 soap 1 3 water is recommended Any bubbles that are visible indicate a gas leak If a gas leak is detected tighten the affected joints and connections If tightening the connections fails to stop the leak replace the affected component and repeat the gas leak test Hidden gas leaks can cause a flashback in the machinery compartment THIS CAN CAUSE SEVERE INJURY OR 1 WARNING FIRE EXPLOSION HAZARD DEATH Stand well clear when switching on the heating circuit 5 3 If no leaks are detected by the test switch on the oven Switch on the heating circuit to ignite the main burner 5 4 With the burner in operation paint all gas pipe joints with the solution of soap and water 5 5 If any further gas leaks are detected shut down the oven Reseal and tighten the affected joints and connections If tightening Page 2 of 4 the connections fails to stop the leak replace the affected component s and repeat the gas leak test 136 P Jan 98 Rev B p n 36862 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 36863 Gas Conversion Kit for PS360EWB WB70 with Midc
54. Flexible Plastic Tubing 15 22450 0297 22450 0297 Mounting Bracket 1 35900 0523 35900 0523 8 32 x 3 4 Screw 2 21278 0002 21278 0002 4 4 1 Aluminum 10 32 x 5 8 Screw 2000227 2000227 j 10 32 Hex Nut 21126 0007 21126 0007 _ Normally Kit Instruction Sheet 35623 35623 Closed Open Switch oven controls to OFF Switch OFF the electrical power supply to the oven at its main disconnect switch or circuit breaker Turn off the main gas supply valve on the gas pipe line Label each wire on the old Air Switch identifying it with its terminal name The replacement Air Pressure Switch has the same ma oo ae terminal names with the same functions Figure 1 shows the Figure 1 Old Air Switch terminal names and locations for the old Air Switch Detach the old Air Switch from its mounting by removing its mounting hardware but do not remove any wires until you have labeled them as Aluminum Tubing instructed in step 2 from oven Plastic Tubing Observe whether the aluminum tubing from the oven connecis to the to Air Switch 7 front or rear fitting of the old Air Switch Loosen the nut that fastens the aluminum tubing to the old Air Switch disconnect the tubing 1 2 3 4 Disconnect the wire complete the removal of the old Air Switch 13 mm 19 mm Figure 2 Tubing Connection Using a tubing cutter or similar tool cut the aluminum tubing near the bend where it
55. For these reasons the best way to optimize heat transfer is by regulating the convection air This can be done in two ways Adjusting the blowers and blower speed to change the quantity and velocity of air delivered onto the product Adjusting the air finger configuration to change the pat tern in which the vertical columns of air are delivered to the product BLOWERS AND BLOWER SPEED PS200 series ovens PS200 series ovens have a single blower motor mounted inside the machinery compartment with a pulley on the end of the motor shaft A belt connects this pulley to another on the shaft of the blower fan The air veloc ity can be changed by using a larger or smaller pulley on motor shaft and changing the length of the belt to match the new pulley See Figure 1 However note that there are only two approved belt pulley combinations for PS200 series ovens one for 60Hz ovens and one for 50Hz ovens Field modifica tions to these approved combinations are not permit ted unless under the specific directions of the Middleby Technical Service Department Any changes to con vection air delivery MUST be made using the air fin gers Figure 1 Blowers belts and pulleys PS360 series PS200 series PS555 570 series PER SII Early NS be 570 Bip oe mcd EL ge Current ee 55705 se2 PS570G all 5555 Blower Wheel
56. Lower air fingers have wire rack as shown to prevent conveyor belt from rubbing on outer plate o Rivets 8222 5558853 gt Inner plate 2558882222 Shutter Manifold Figure 4 Current standard air finger all oven models Outer plate Width and hole configuration varies Inner plate Width and hole configuration varies May have inner dam Manifold Width varies to match inner and outer plates Baffle may be solid perforated partially perforated or absent Several special shapes are available to meet specific customer needs Configuration and Alignment To ensure proper baking of the product the air flow MUST be properly aligned as it exits the air fingers Because air finger configurations are tested at the fac tory for a specific customer s product severe bake prob lems related to the air fingers are rare If you encoun ter a problem check the following 1 Check that the air fingers are properly assembled cleaned and free of obstructions For the standard air fingers shown in Figure 4 a variety of styles are available for each of the three components It is often possible to assemble these components in correctly as they are designed to be modular This will affect the quality of the bake If you need information on the correct air finger con figuration of the oven check the following 3D air finger label card Many current ov ens will have a three dimen
57. Middleby ovens use one of the following systems for gas flow regulation On Off gas flow regulation These ovens are equipped with a high flame solenoid valve The solenoid valve can only be positioned fully open 10096 gas flow or fully closed 096 gas flow as necessary to maintain the set point A bypass line supplies gas to maintain the flame when the valve is closed On off gas systems have a temperature swing of several degrees on either side of the set point On Off gas flow regulation is used on the following Middleby oven models PS200 series PS360WB through 3 02 PS360WB70 PS310 PS570S PS314 through 8 00 PS360 Additional information on the solenoid valve is pro vided in Solenoid Valve on Page 96 Modulated gas regulation These ovens are equipped with a modulating gas valve The modu lating valve can open or close at any setting from 0 10096 gas flow in response to the need for heat to maintain the set point Because of this flexibility the temperature swing is eliminated The modulated gas system is used on the following Middleby oven models PS200 series PS5708 4 02 or later 9 00 or later PS360EWB PS570G PS555 Additional information on the modulating valve is provided in Modulating Valve on Page 97 Figure 62 Wayne burner PS360EWB shown For different oven models refer Main gas line to the drawings on pages 88 90 Burner Air shutter blo
58. PS555 all 55705 units produced 4 00 or later pagina IMPORTANT THIS CONVERSION KIT IS INTENDED FORAGA CGA AND CSA APPROVED MIDDLEBY MARSHALL GAS FIRED OVENS OPERATING AT ALTITUDES UP TO 5000 FT 1524m FOR OVENS INSTALLED AT ALTITUDES ABOVE 5000 FT 1524m CONSULT THE FAC TORY BEFORE INSTALLING THIS KIT THIS KIT MAY NOT BE USED WITH CE APPROVED MIDDLEBY MARSHALL OVENS FOR THESE OVENS FOLLOW THE GAS CONVERSION INSTRUCTIONS IN THE NSTAL LATION SECTION OF THE 5 OWNER S OPERATING AND INSTALLATION MANUAL 1 lt 7 WARNING THIS CONVERSION KIT IS BE INSTALLED BY AMIDDLEBY MARSHALL AUTHORIZED SERVICE AGENT INACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS AND ALL CODES AND REQUIREMENTS OF THEAUTHORITY HAVING JURISDICTION FAILURE TO FOLLOW INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR PROPERTY DAMAGE THEAUTHORIZED SERVICE AGENT PERFORMING THIS WORKASSUMES RESPONSIBILITY FOR THIS CONVERSION WARNING BEFORE PERFORMING ANY SERVICE WORK THE ELECTRICAL POWER SUPPLY AND THE GAS SUP PLY MUST BE TURNED OFF P N 88210 0070 Rev C V1 8 00 125 SECTION 3 SERVICING COMPONENTS Appendix Instructions for All Gas Conversion Kits for Ovens with Wayne Burner Propane to Natural Gas 8 00 Typical PS200 series gas train configuration Solenoid Pilot line Combination gas control valve He safety regulator E VI x Burner Pilot pressure tap pilot te
59. Pickup Wires on Early PS360 series Ovens 19 Types of Heat Transfer 21 2424 24 7 Ki Appendices tc hia Be 20 Blowers and Blower Speed 7 Conveyor sensor wiring changes PS360 series 5200 7 55705 10 95 20 5360 ovens 8 e Service Bulletin MM 133B Installation Instructions C 5555 570 OVENS iss 8 for Gonyeyor speed Controler Kit with Thumbwheel S P N 42810 0133 4 95 21 Fingers e ER tete cate 4 E A Description and Function Instructions Service Kit 42810 0133 Conveyor Speed Controller Kit with Thumbwheel 4 95 23 B Gonfiguratonand Alignment Service Bulletin 177 Introduction Compat C Performing a Test Bake ibility of Conveyor Speed Controller with Digital D PS300 350 Air Finger Shutter Adjustment 10 Display P N 37337 8 00 27 IV Oven Capacity ania sedeo elio ee un 12 Instructions for Service Kit 44756 Conveyor Speed A Conveyor Speed and Bake Time 12 Controller Kit for PS200R68 series Ovens
60. Reference sections on Pages 140 and 142 respectively 1 PS200 series mercury contactor replacement Remove the complete contactor from the oven Then remove the terminal clamps from the contactor tube s to be replaced Locate the Tinnerman clips on the bottom side of the contactor that hold each individual contact tube in place Find the break in the tube bracket located in the center Then using a diagonal cutter cut the Tinnerman clip so that it may be removed Remove the contact tube If the coil must be re placed all three contactor tubes must first be re moved To replace the contactor tube s slide the thin end of the tube into the contactor bracket 146 Figure 84 Figure 86 SECTION 3 SERVICING COMPONENTS Support the wide end of the tube between two Figure 87 pieces of wood so that the terminal end will not be 7 damaged Place a deep well socket over the new Tinnerman clip Figure 89 e Gently tap the socket with a hammer to push the clip down and into place NOTE When replacing the mercury contactor into the oven the widertube ends must be pointing UP The tubes must ALWAYS be mounted in a vertical position 147 SECTION 3 SERVICING COMPONENTS 2 PS310 360 series contactor replacement Figure 90 Remove the two Phillips head screws holding the cover in place Then remove the cover Remove the six terminal lug screws This pro
61. Restore the electrical and gas utility connections to the oven Paint all gas pipe connections from the union to the venturi mounting plate as well as the pilot tubing bypass tubing and pressure tap plug with a rich solution of soap and water 2 3 soap 1 3 water is recommended Any visible bubbles indicate a gas leak If a gas leak is detected tighten the affected joints and connections Iftightening the connection s fails to stop the leak Turn off the electric power supply to the oven Turn off the gas supply service valve behind the oven Replacethe affected component s Repeat the gas leak test WARNING FIRE EXPLOSION HAZARD HIDDEN GASLEAKS CAN CAUSE A FLASHBACK IN THE MACHINERY COMPARTMENT THIS CAN CAUSE SEVERE INJURY OR DEATH STAND WELL CLEAR WHEN SWITCHING ON THE HEATING CIRCUIT If no leaks are detected by the test depress the safety Switch es and switch onthe oven Then switch onthe heating circuit to ignite the burner With the burner in operation paintall gas pipe joints with the solution of soap and water If any further gas leaks are detected shut down the oven Reseal and tighten the affected joints and connections Iftightening the connection s fails to stop the leak Turn offthe electric power supply to the oven off the gas supply at the service valve behind the oven Replace the affected component s Repeat the gas leak test 1 2 Using a manometer ch
62. SECONOARY 24V 65 2 is 2 A A POLY NO 1 2 COM t 2 153 ALA FR 9 e NO 2 PRIMARY 240 2680 55 50 60 Hz SECONDARY 120V Bs 200va 555 gas oven early 208 240V main blower motor and control circuit 208 240V 50 60 Hz 1 Ph 2 pole 3 wire supply 2 hot 1 ground CONVEYOR SPLIT BELT ONLY 4 POLE MAGNET CONV MOTOR RPM PICK UP CONTROLLER POLE RPM PICK UP CONVEYOR CONTROLLER SINVHOVIO ONISIM 0819 NOLLO3S TEZ 011 RED COOLING FAN LH LEAD 5 53 gt uu CONVEYOR mi CONTROLLER WH TO HL TC RED TO H TC GRD TO HL GRD 2 NO 2 con 2 2 REAR PANEL GROUND FRONT 50760 nz SECONDARY 1207 200 2 a v 2 KFAR PRIMARY 240 280 m BeN lerr s BLWR 2 BLU PUR IRED BLK RED BLK R R LEAD 4 45 12 58 9 o 2 PICK UP NO wr COOLING AIR SWITCH 2 AIR SWITCH 1 FAR n REAR LEFT REAR RIGHT i n 7 LEAD 2 AR SWITCH 3 14 ot FRONT RIGHT xFMR3 165 5 14 PRIMARY 2407 50 60 SECONDARY 24V 25V c 163 2 MODULATING V conv a gt PLOT
63. TC White wire to thermocouple DO NOT CUT THIS WIRE TO LENGTH d Terminal TC Red wire to thermocouple DO NOT CUT THIS WIRE TO LENGTH f Terminal L2 White wire kit supplied to neutral on the oven s terminal block h Terminal Orange wire originally to UE control Using a 1 4 wire connector attach a brown kit supplied wire to the L1 terminal on the high limit control Attach the free end of the wire to the L1 terminal on the temperature controller Page 4 of 8 SECTION 3 SERVICING COMPONENTS 22 23 Appendix Instructions for Service 39733 High Limit Conversion Kit for PS300 310 350 amp 360 Ovens 5 99 TESTING THE INSTALLATION Remove the thermocouple wires from the TC and TC terminals on the high limit control Attach a Middleby Marshall Thermocouple Source P N 27170 0263 to the TC and TC termi nals on the high limit control in place of the thermocouple wires Note that it may be necessary to attach a pair of terminal connectors to the leads of the Thermocouple Source to allow them to connect to the high limit control s terminals Restore the gas supply if so equipped and the electrical supply to the oven Because the control compartment door is still open pull the door safety switch out into the service position Test the operation of the high limit control as follows a Setthe Thermocouple Source
64. There is a fourth lead on one end of the shielded cable This is a ground lead which is attached to the black wire ofthe cable The ground lead should be connected to the terminal block inside the motor compartment Current PS360 series ovens have the shielded cable installed at the factory and do not require this retrofit SECTION 3 SERVICING COMPONENTS Figure 20 ae Wiring for PS360 Shielded Green Ground Pickup Cable early terminal YO Red block design Black Cable Controller Black Wires oe Green White Shieided Cable Figure 21 Wiring for PS360 Shielded Pickup Cable late terminal block design ele Ground Shieided Cable White K Appendices remove cable shield connection dotted line from terminal 4 neutral DC conveyor 120VAC line conveyor switch conveyor motor RPM pick up conveyor speed setting terminal block Ground sheilded cables at one end only to prever ground loops conveyor speed control connect cable shield removed from a second speed control terminal 4 to terminal 3 is used on split belt and add ground wire from applications terminal 43 to chassis ground SECTION 3 SERVICING COMPONENTS Appendix Service Bulletin 133 Installation Instructions for Conveyor Speed Controller Kit with Thumbwheel P N 42810 0133 4 95 Middleby Bulletin No MM 133B Marshall Date 04 07 95 Toastmaster Middleby Cooking S
65. a kit that also includes the new clamp This allows you to attach an existing pickup assembly to a new motor In 7 01 and 8 01 some of the new motors were shipped under the part numbers of the old motors These parts shipped without the new clamp In most of these cases you can tighten the existing clamp to fit the new motor Some older clamps however cannot be tightened enough to fit To be sure that you can install the new motor in all ovens you should add the new clamp P N 46602 to your required parts stocking list and carry a few spare clamps on each service vehicle Please be aware of these changes as you order your stocking parts Some versions of the old motor as well as the old style pickup assembly are still available in limited quantities The brush for the old motor P N 22450 0052 will remain available in order to maintain motors already in the field Old Old Old New New New New Ratio Used on Motor Brush Pickup Motor Brush Pickup Clamp 1400 1 5310 27384 0008 22450 0052 27170 0263 46603 46658 46451 46602 PS314 PS360 360S PS360SS High Speed PS360T Tandem PS360WB PS360WB70 PS360EWB 5555 5570 5705 Single Belt 1350 1 PS200 220FS 224 27384 0011 22450 0230 27170 0263 46604 46658 46451 46602 PS200VL 220VL 224VL PS200R68 220R68 224R68 PS200T Tandem 5570 5705 Split Belt Standard 600 1 PS314SBI 27384 0003 22450 0052 27170 0263 46605 46658 46451 46602 300 1 5200 220 5 224 High Speed 2
66. as outlined in the procedure on sheet 1 of these instructions IX PS570 570S FLAME GATE B All PS570 570S ovens produced for Pizza Hut USA through 8 00 were equipped with an adjustable flame gate at the end of the burner tube The purpose of the flame gate was to direct heat towards the entrance end of the oven to bet ter suit the customer s cooking needs PS570S ovens produced 9 00 or later as well as all PS570G ovens are not equipped with the flame gate The introduc tion of the modulating gas system to these ovens as well as improvements to the customer s air finger configuration and baking specs make the flame gate unneccessary on these ovens A Part Number Reference Flame Gate Part No Description 35210 0555 Flame gate 35210 0511 Adjustment rod 35210 0510 Clamp Figure 53 SECTION 3 SERVICING COMPONENTS Flame Gate Orientation To check the position of the flame gate view it through the oven s window See Figure 53 The gate must point towards the EXIT end of the oven Note that this directs the flame from the burner tube towards the EN TRANCE end of the oven as described above All ovens were originally shipped from Middleby Marshall with the gate pointing to the right This is because all ovens were shipped with left to right conveyors Ifthe conveyor direction of one of these ovens is reversed in the field the flame gate should be repostioned as fol lows Loosen do not remove the tw
67. behind the oven Replacethe affected component s Repeat the gas leak test WARNING FIRE EXPLOSION HAZARD HIDDEN GASLEAKS CAN CAUSE A FLASHBACK IN THE MACHINERY COMPARTMENT THIS CAN CAUSE SEVERE INJURY OR DEATH STAND WELL CLEAR WHEN SWITCHING ON THE HEATING CIRCUIT If no leaks are detected by the test depress the safety switch es and switch on the oven Then switch on the heating circuit to ignite the burner With the burner in operation paintall gas pipe joints with the solution of soap and water If any further gas leaks are detected shut down the oven Reseal and tighten the affected joints and connections If tightening the connection s fails to stop the leak Turn off the electric power supply to the oven off the gas supply at the service valve behind the oven Replace the affected component s Repeat the gas leak test INLET PRESSURE CHECK 1 2 Using a manometer check the inlet pressure at the inlet pressure tap See Figure 6 An inlet pressure of 6 12 W C 14 9 29 9mbar is recommended for natural gas operation If the inlet pressure is HIGHERTHAN 14 W C 34 9mbar This pressure may damage the combination gas control valve safety regulator The gas supply pressure should be decreased LOWER THAN 6 W C 14 9mbar It may be necessary to increase the supplied gas pressure CAUTION IF IT IS NECESSARY TO ADJUST THE GAS LINE PRESSURE HAVE THE CUST
68. contains an excessive quantity of air and will not burn Of concern is the second or combustion area This is where the burning occurs and is the area that is of prime importance for good flame sensor location Flame Rectification With flame rectification two probes with different sur face areas are exposed to a flame in this case the pilot flame The probe with the larger surface area at tracts more free electrons and as a result becomes the negative probe Therefore current is conducted through the flame from the positive probe to the nega tive probe See Figure 67 Note also that the AC voltage sine wave has not changed but the negative portion of the current sine wave has been chopped off This positive portion now represents a DC current This is the phenomenon of flame rectification To apply this principle to an IID Intermittent Ignition Device in this case the pilot ignitor assembly a pilot and flame sensor have been substituted for the two probes See Figure 68 After the pilot is ignited a DC current flow 012 0 microamps or more is conducted through the flame from the flame sensor the positive probe to the pilot tip the negative probe The pilot tip acting as the negative probe completes the circuit to ground The IID sensing circuit uses this DC current flow to energize a relay and open the main burner gas valve 94 Figure 67 Flame rectification _ FLAME NEGATIVE PROBE G
69. current version 71 SECTION 3 SERVICING COMPONENTS 6 Current style PS200 bearing replacement and alignment NOTE This procedure is for current style indirect fan shaft assemblies only as shown in Figure 26 Bearing replacement procedures for the early style indirect fan shaft assembly Figure 25 are provided on Page 70 The following procedures are necessary to align the fan shaft whenver service to the fan shaft or replace ment of the bearings is required REFER TO FIGURE 34 FOR ILLUSTRATIONS OF THE COMPONENTS DE SCRIBED HERE 1 Remove the entire back wall 1 of oven to service the fan assembly 2 Remove the blower fan Item 11 and pulley Item 7 3 Remove the indirect drive bracket assembly Item 5 by removing eight 8 screws Item 2 If you are upgrading from the early style assembly save the hardware Items 2 3 4 and 12 to be reused with the new style bracket Item 5 NOTE If parts to be replaced you should replace them now 4 Install front and rear fan shaft pillow block bearings Item 9 if they were removed to indirect drive bracket Item 5 using two 2 3 8 16 X 1 screws Item 2 and two 3 8 lockwashers Item 10 on each bearing NOTE Do not tighten the pillow block bearings until Step 7 has been completed 5 Install the fan shaft Item 6 as illustrated in Figure 34 Align bearing set screws with flats on shaft but do not tighten set screws at this time NOTE
70. each of which contains three elements Elements CAN NOT be removed from the assembly Each element has a cold unheated end next to the connecting leg 12 0 3m leads are connected to the cold ends for easy connection to the termi nal blocks on the back wall of the oven e Individual element electrical data Volts Watts Ohms Connection 208V 266771 1620 Parallel 220V 2241W 2160 Parallel 230V 2449W 2160 Parallel 240V 2667W 2160 Parallel 380V 2667W 5410 Parallel 416V 2003W 8640 Parallel 480V 266771 8640 Parallel Checking the Heating Elements The most common problems encountered with electric heaters are Open or bad connections Open shorted or grounded heating elements To troubleshoot the heating elements disconnect all leads at the terminal blocks on the back wall Then check each element with a digital multimeter set to Ohms Q Correct ratings are shown in the table in the preceding section Zero reading on the ohm scale indicates an open or shorted element is also possible to check for an open element using an ampmeter Any current through the element indi cates that the element is not open 6 Changing Heating Elements NOTE Wires going from the controller assembly contactor to the heating elements are rated at 392 F 200 C DO NOT under any circumstances use a wire of lesser rating or quality To remove the element Remove the blower belt on the affected side of the oven Remo
71. eee 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 UUN gt SECTION 5 25 point preventative maintenance checklist Check and clean blow out machinery control compartment Check and clean blow out main blower motors Check and clean blow out and brush axial fans Check burner blower motor and fan operation Check and clean igniter assembly Check and clean all orifices Install pilot tee if oven is not so equipped Check gas pressures adjust as necessary Check air fuel mixture adjust as necessary Check ignition cable for signs of deterioration Check and tighten all electrical connections Inspect conveyor belt for damage repair as necessary Inspect conveyor frame pivot plates Inspect conveyor shaft bushings Replace drive side bushing Check conveyor drive chain tension adjust as necessary Verify proper air finger arrangement correct as required Inspect and clean vacuum conveyor motor and motor brushes Inspect conveyor motor sensor and magnet verify correct spacing adjust as necessary Check conveyor speed control verify belt speed to be within 10 seconds of set point Verify that proper number of thermocouples are installed Check temperature control with thermocouple source to verify accuracy Check high limit safety circuit with thermocouple source to verify correct operation Check cool down feature with thermoco
72. lead thermocouple that sends a signal to both the temperature controller and the high limit control module Referto Thermocouples on Page 54 for details If the temperature sensed by the high limit thermocouple exceeds 650 F 343 C the high limit control module will shut down the oven and illuminate the green reset button The module will need to be reset by pressing the reset button before the oven can be operated The reset button is located inside the machinery compartment to ensure that itis reset by an authorized service agent The agent should determine and correct the cause of the high limit condition before returning the oven to service An open high limit thermocouple will trigger the high limit control module to shut down the burner The high limit control will need to be reset after the open is corrected as per the procedure described above before the oven can return to operation Figure 23 High limit control modules Shown in PS360 series oven United Electric Type 54 high limit control module United Electric Type 55 high limit cooldown control module Watlow high limit control module D Appendices SECTION 3 SERVICING COMPONENTS Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 USA 847 741 3300 FAX 847 741 4406 Instructions for Service Kit 39733 Appendix Instructions for Service Kit 39733 High Limit Conversion Kit for PS300 310 350 amp 360 Ove
73. leads or the remote leads at the terminal block con nection To reverse the conveyor motor direction simply inter change the black and red leads 2 To Start the test the dimmer switch should be turned until the motor begins to operate The switch can then be turned down to the desired motor speed Figure 18 Field Tester for Conveyor Drive Motor To Motor Terminals of Conveyor Terminal Block DIMMER or circuit breaker 110V White SECTION 3 SERVICING COMPONENTS E Basic Troubleshooting Flowcharts 1 IF THE GEAR MOTOR RUNS AT FULL SPEED All wiring between Controller Magnetic Pickup and Motor in good condition Check for 120VAC Repair wire to Speed Controller connection Complete the Conveyor Controller Pickup Test Page 19 Pass Current version Original version Replace magnetic with DIP switches with pickup Check that DIP interchangeable switch settings are microcomputer correct for oven Replace model microcomputer Conveyor still Correct DIP switch runs too fast settings Complete the Conveyor Motor Test Page 19 Conveyor still runs too fast Replace motor Replace conveyor speed controller NOTE Middleby no longer stocks parts for the original speed controller with interchangeable microcom puter If it is necessary to replace this version of the controller or the microcomputer and the service agent does not have the parts in stock it wil
74. necessary current is not being maintained and a shutdown of the system will result The positioning of the flame sensor is also critical in the pilot application Positioning of the flame sensor should be such that it will be in contact with the sec ond or combustion area of the pilot flame Passing the flame sensor through the inner cone of the pilot flame is not a recommended procedure Forthis rea Son a short flame sensor may provide a superior sig nal over a longer one The final determination of the sensor location length is best determined by the use of a multimeter set to read microamps Figure 69 Air shutter adjustment Wayne burner Standard openings 1 4 6 4mm for natural gas ovens 3 8 9 5mm for propane ovens Loosen hex Counter Clockwise clockwise less air putto adjust more air shutter Midco burner Standard opening 5 16 7 9mm all gases Clockwise Counterclockwise less air Loosen more air screw to adjust shutter SECTION 3 SERVICING COMPONENTS G Burner Transformer 120V burner blower motors feature a transformer located in the electrical junction box on the burner In PS570S ovens AND all ovens with 208 240V burner blower motors the transformer is located inside the machinery compartment The transformer supplies 24V to the burner motor relay if present and also to the 24V gas valve through the motor s centrifugal switch or air pressure safety switch
75. new Speed Controller units and save your remaining thumbwheel controls for use with the oven models that cannot use the new controller APPLICATION Service agents should immediately begin to stock P Ns 37337 and 37503 to fulfill their normal need for conveyor speed controllers The new units can be used without modification on ALL OVENS EXCEPT THE PS200R68 SERIES Your existing stock of P Ns 42810 0133 and 42810 0118 should be used whenever possible ONLY for PS200R68 series ovens The new speed controller and digital display are already in use on Middleby Marshall PS555 ovens your Agency may already have some of these components in stock Please check your exist ing stock of these components before placing addtional orders COMPATIBILITY The Speed Controller with Digital Display is compatible with all Middleby Marshall ovens EXCEPT the PS200R68 PS220R68 and PS224R68 AVAILABILITY e 37337 37503 are available for immediate shipment e P N 42810 0133 is available in very limited quantities Note that some future orders may not be fulfilled P N 42810 0118 is no longer available SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 44756 Conveyor Speed Controller Kit for PS200R68 series Ovens 2 02 Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 USA 847 741 3300 FAX 847 741 4406 o Middleby 2728 Marshall Instructions for Service Kit 44756
76. other In these ovens the upper thermocouple senses the oven temperature and is con nected to the temperature controller The lower thermo couple is connected to the high limit control module Ei ther thermocouple can be replaced using this Kit Remove the lower end plug from the control end of the oven Then remove 1 or 2 lower air fingers as neces sary to access the thermocouple mounting tube Refer to Figure 1 REMOVE AND DISCARD the set screw and pull the thermocouple out of the mounting tube Disconnect the thermocouple wiring from the tem perature controller or high limit module as appropriate Remove AND RETAIN the 10 16 screw that fastens the flange of the thermocouple mounting tube to the plenum wall Leave the mounting tube in place Install the new thermocouple so that its flange fits firmly against the mounting tube flange Replace the 10 16 screw that you removed in Step 3 Check that the head of the screw holds the thermo couple flange securely in place as shown in Figure 1 Route the thermocouple leads away from the ignition cable Connect the leads as shown in Figure 2 PS200 Series 2 96 or later serial numbers after ASH 0001 Thermocouples on these ovens are located in the same position as the earlier PS200 models described above However these ovens feature a flanged thermocouple iden tical to the new thermocouple provided in this Kit The thermocouple SHOULD be held in place by the screw tha
77. ovens are all connected to the terminal block inside the left blower motor compartment It is not necessary to access the right blower motor compartment Figure 16 2 Remove the screws that hold the thermocouple to the wall Slide the thermocouple out of its mounting hole Disconnect the thermocouple leads from the terminal block Remove and discard the thermocouple Install the new thermocouple into its mounting hole Fasten it in place with the supplied 6 x 3 8 screws Wire the thermocouple as shown in Figure 16 Note that the terminals are labeled TC for temperature sensing thermocouple leads for ground leads and HL for high limit thermocouple leads Use the kit supplied nylon clamp and 10 16 x 3 4 screw to secure the thermocouple leads so that they will clear the shrouds blower belts and pulleys Replace all shrouds onto the oven Thermocouple Wiring PS555G and PS570G Red White temp Ground temp leads all Red White hi lim hi lim Ig HL P di P To temperature controller To ground terminal on temp controller D To mounting screw To high limit control module for high limit control module gt Middleby 7728 Marshall Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 847 741 3300 FA
78. ovens that do NOT include a separate high limit control module this includes most PS200 series and PS360 series gas ovens this thermocouple signal is used to monitor the oven temperature for regulating the gas flow heater activation AND to activate the high limit warning in case of an overtemp condition Middleby ovens use from one to three temperature sens ing thermocouples depending on the oven model Temperature sensing thermocouples are used on all oven models and are connected to Terminals 7 and 8 on the temperature controller Based on the signal from this thermocouple the temperature controller e Calls for heat from the burner heating elements to maintain the set point output from Terminals 4 amp 5 for on off electric and gas ovens output from Ter minals 15 amp 16 for variable pulse electric and modu lating gas ovens Controls the cooldown feature if the HEAT switch is turned off while the oven is above the cooldown temperature output from Terminals 9 amp 10 Onovens without a separate high limit control mod ule most PS200 series and PS360 series gas and electric ovens the oven temperature sensed by this thermocouple is also used to activate the high limit warning output from Terminals 11 amp 12 54 Figure 24 Thermocouples Cable flange 3 leads Current 3 lead P thermocouple Cable 2 or 4 leads Obsolete 2 lead 4 lead thermocouple clip A Part
79. p n 31822 into the orifice holder Tighten it to a snug fit Replace the main orifice holder into its opening in the burner plenum Tighten it to a snug fit LOW FLAME ORIFICE REPLACEMENT PS360WB70 only Unscrew the brass fittings at both ends of the aluminum low flame tubing This allows the tubing to be removed See Figure 4 Remove and retain the tubing from the solenoid valve Remove and discard the low flame orifice from the end of the low flame tubing Insert the new propane low flame orifice p n 22174 0009 into the discharge end of the low flame tubing as shown in Figure 4 Replace the low flame tubing into the fittings on the solenoid valve Screw in the brass fittings at both ends of the aluminum low flame tubing Tighten them to a snug fit GAS LEAK TEST Paint all pipe connections from the gas union to the burner plenum and the aluminum pilot and low flame orifice tubing connections Figure 2 Pilot orifice assembly Pilot tubing connector Pilot tap plug Pilot orifice Figure 3 Main orifice and holder Main orifice Qo holder Main orifice Main manifold tap plug leave in place Figure 4 Low flame orifice replacement Aluminum Low flame orifice Solenoid valve with a solution of soap and water 2 3 soap 1 3 water is recommended Any bubbles that are visible indicate a gas leak If a gas leak is detected tighten the affected joints and connections If tightening the connections fa
80. phase blower motors Three 5A fuses Fuse location is shown in Figure 36 In addition each motor contains a centrifugal safety switch that prevents the burner heating elements from activating if either motor is not operating See Blower Motor Centrifugal Safety Switch on Page 80 The blower wheel is directly connected to the motor shaft A heat slinger also mounted on the motor shaft helps to keep heat away from the motor bearings If the motor is stopped when the temperature in the compartment is over 180 F 82 C the bearings can be damaged 1 Part number reference Blower motors Part Number Description 27381 0023 1 Ph 1 3 hp 5310 314 360 360S 27381 0024 3 Ph 1 3 hp PS310 314 360 27381 0054 1 Ph 1 4 hp PS360Q 27381 0075 1 Ph 1 2 hp PS360WB 31432 1 Ph 1 hp PS360EWB WB70 Blower wheels Part Number Part Number clockwise counter clockwise Description 22523 0002 22523 0003 9 3 16 233mm dia PS310 314 360 360Q 3605 360WB 35603 35604 9 1 8 232mm dia PS360EWB 36014 36015 8 1 4 210mm dia PS360EWBQ 31599 31600 9 7 8 dia 251mm PS360WB70 Other components Part Number Description 27396 0005 Heat slinger 42400 0101 Blower wheel puller tool 2 Blower balancing All blower wheels are balanced at the factory Any blower wheel found to be out of balance should be re placed Vibration from an out of balance wheel can cause poo
81. reduced below the room temperature For a PS360WB70 oven set the oven to low flame Figure 6 Gas pressure measurement adjustment locations Measure the pilot pressure as shown in Figure 6 The gas Pressure Pilot tube pressure should be 5 6 W C 12 5 14 9mbar for proper operation regulator cap connects screw If necessary adjust the pilot pressure as follows Remove the pilot adjustment cap screw Using a screwdriver turn the inner adjustment screw counterclockwise to increase clockwise to decrease Pilot the pilot gas pressure Inlet pressure adjustment Replace the cap screw tighten it firmly inn cap screw Measure the current across the pilot flame sensor The current must measure at least 2 0 uA If the current reading is too low recheck the pilot pressure as per Step 7 3 If the A E pressure reading is correct consult the factory otherwise M Main orifice repeat Steps 7 4 and 7 5 pressure tap MAIN MANIFOLD PRESSURE ADJUSTMENT With the oven set to high flame measure the regulated gas pressure to the burner The outlet pressure should be checked at the main orifice pressure tap See Figure 6 The gas pressure should be 3 W C 7 46mbar for proper Pilot pressure operation tap If necessary adjust the pressure regulator as follows Remove the pressure regulator cap screw Using a screwdriver turn the inner adjustment screw clockwi
82. remote board Then remove and dis Open the machinery compartment door and locate the card the thumbwheel unit conveyor speed control module Remove and discard the cable Install the new digital display unit in place Connect its One at a time disconnect the leads from the terminals on ribbon cable plug into its socket on the remote board the existing speed control module and connect them to the corresponding terminals on the new control module Close the remote box and reinstall it atop the oven Install the new kit supplied control cable between the back of the remote box and the back of the machinery compart ment Remove the ribbon cable plug from its socket on the old speed control module and attach it to the corresponding Socket on the new control module Remove and discard the old control module from the in Restore the electrical and gas utility supplies to the oven side of the machinery compartment door Test the operation of the new conveyor speed controller to make certain that it is operating properly The oven is now Adjust the DIP switch settings on the new speed control ready for operation module to the correct settings for the PS200 series oven with a 3 30 minute bake time range These settings are Middleby DIP Switch Settings OFF ON Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 847 741 3300 FAX 847 741 4406 Middleby Corporation Service H
83. s protective sheath The ground connection helps to drain any radio frequency disturbances from the thermocouple before the signal enters the temperature controller or high limit control module For a temperature sensing thermocouple the ground lead MUST be connected to the ground terminal on the temperature controller For a high limit thermocouple the ground lead should be connected to a chassis ground or to the mounting screw for the high limit control module Some early thermocouples may have either two or four leads The two lead thermocouple is simply an earlier version of the current model without the ground lead When replacing a two lead thermocouple it will be necessary to connect the new ground lead The four lead thermocouple is actually a dual function unit which sends its signal to both the temperature controller and the high limit control module Current ovens use separate thermocouples for these functions When replacing a four lead thermocouple it will be necessary to use a SECOND KIT to install the high limit thermocouple In addition any oven equipped with these early thermocouples should have all of its thermocouples updated at the same time For a 5570 or PS5708 oven this will require THREE THERMOCOUPLE KITS two for the existing thermocouples and one for the new separate high limit Oven Model Oven Model Page PS200 Series before 2 96 serial numbers before ASH 0001 PS555 Gas rear wall thermocouples with screw termi
84. same terminals as all terminals are numbered the same EXCEPTION Controller P N 32571 Fig 1E used on early PS360EWB ovens only uses Termi nals 4 amp 5 for the mA output to the amplifier board The current controller uses Terminals 15 4 16 for these connections as shown in Figure 5A Page 4 of 10 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 47321 Digital Temperature Controller Kit 2 02 Figure 4a Figure 4b Analog temperature controller P Ns Analog temperature controller 28071 0012 and 28071 0018 terminals P N 34983 terminals New temperature New temperature controller terminals controller terminals m Suge Not used PS200VL ovens have a sepa rate high limit module and do not include a cooldown feature Not used Not used PS200VL ovens do not include a modulating gas system 1 2 Not used 5 6 L2 L1 G 13 TC 14 Not used TC some gas and 15 electric ovens Not used 16 COM NO Not used L2 Not used These 11 49 4 65 65 49 terminals provide PID output gas ovens G with modulating valve or variable
85. screw Resetthe oven s set point temperature to the customer s original settings Leave the oven in operation to allow the manifold pressure to be checked in the next Section of these instructions Figure 7 Flame sensor Pilot hood 1 MANIFOLD PRESSURE ADJUSTMENT Remove the regulator cap screw from the combination gas control valve Using a manometer check the pressure at the manifold pressure tap as shown in Figure 6 A manifold pressure of 10 W C 24 9mbar is recommended for propane operation Adjust the pressure as necessary by turning the adjustment screw on the combination gas control valve Turning the screw clockwise decreases the pressure Turning the screw counter clockwise increases the pressure If the manifold pressure cannot be properly adjusted switch the oven off and allow it to cool then replace the combination gas control valve RepeatSection VII Gas Leak Test before attempting to adjust the manifold pressure again Afterthe manifold pressure has been properly adjusted replace the cap screw Record the final value on the Gas Conversion Label as shown in Figure 8 Switch the oven off and allow it to cool MARKING AND LABELING Figure 8 THIS CONTROL HAS BEEN CONVERTED FOR USE WITH PROPANE GAS 22501 0007 Attach to gas piping next to combination gas valve technici Name of an Printthe word PROPANE in the space provided on the G
86. switch will not close and the circuit remains open preventing burner heating el ement activation A Part Number Reference Blower Centrifugal Switch On all PS360 series blower motors the centrifugal switch can be replaced with switch P N 27270 0144 B Troubleshooting 1 access the switch remove the rear motor wiring cover plates See Figure 49 2 When the switch is operating properly both sides of the brown wires coming from the switch should be hot when the motor is at full RPM 3 No adjustment can be made to the switch If it is not operating properly it must be replaced VII BURNER BLOWER MOTOR CENTRIFUGAL SAFETY SWITCH PS200 SERIES GAS PS310 PS314 PS360 PS360WB PS570S Middleby gas ovens with a 120V burner blower motor have a centrifugal safety switch that prevents burner activation if the burner blower motor is not in operation This includes e Most PS360 series ovens except PS360WB70 and PS360EWB e PS200 series gas ovens except units produced with the modulating gas system All Model PS570S ovens Ovens with a 208 240V burner blower motor use a separate air pressure safety switch to prove motor operation See Air Pressure Safety Switch on Page 81 The centrifugal switch is a normally closed NC limit switch mounted inside each blower motor When the motor is not running the centrifugal switch weight holds the switch open As the motor reaches full speed the weight moves a
87. switch with threaded screw type adjustment P N 36194 This switch was used on a limited number of domestic production ovens in early 1997 to cover an availability problem with the standard switch see 2 above ings were in water column inches in W C An export version of this switch was never used This switch was never available as a service part If it must be replaced use Kit P N 35624 see 2 above Yamatake Honeywell air switch non adjustable This switch is the current standard for all new produc tion Middleby ovens You may NOT use this switch as an upgrade on an oven equipped with an older switch Two different models are used one for dometic and standard export ovens and another for CE approved ovens Figure 51 PS360WB70 EWB with Midco burner Connects to Connects to positive pressure side of air switch Domestic switch P N 39530 CE version switch P N 37498 If this switch must be replaced use an identical switch Note that this is the ONLY time that you may use P Ns 39530 and 37498 as service replacement parts Troubleshooting Postive pressure vs negative pressure All air switches except the original round version can sense either positive air pressure or negative air pres sure The connection that is actually made to the switch depends on the application Ifthe switch is used to detect blower operation the tip ofthe pitot tube is located outside of the blow
88. the pilot adjustment screw on the combination gas control valve Turning the screw clockwise decreases the pilot pressure Turning the screw counter clockwise increases the pressure Some valves may have a burr in the pilot adjustment portal If you have fully tightened the adjustment screw and the manometer still does not register a change in pressure continue to tighten the screw to break through the burr Back the screw out until its top is flush with the top ofits hole then tighten the screw again as necessary to adjust the pressure Repeat this procedure as necessary to properly adjust the pilot pressure If the pilot pressure cannot be properly adjusted switch the oven off and allow it to cool then replace the combination gas control valve Repeat Section VII Gas Leak Test before attempting to adjust the pilot pressure again After the pilot pressure has been properly adjusted replace the cap screw Resetthe oven s set point temperature to the customer s original settings Leave the oven in operation to allow the manifold pressure to be checked in the next Section of these instructions Figure 7 Flame sensor Pilot hood Figure 8 THIS CONTROL HAS BEEN CONVERTED FOR USE WITH NATURAL GAS 22501 0007 Attach to gas piping next to combination gas valve Name of technician MANIFOLD PRESSURE ADJUSTMENT Remove the regulator cap screw from the combination gas control valve Using a ma
89. the metal washer rubber washer and Coupling Nut up the wires and into the coupling hole on the Air Pressure Switch screw the Coupling Nut finger tight to hold the wires Adjust the setting of the dark rim around the blue center knob so that the white triangle is touching A Onan Air Pressure Switch with a UL symbol on the blue label the 0 16 value OR B Air Pressure Switch with a DIN symbol on the blue label the 0 4 value Reinstall the clear plastic cover on the Air Pressure Switch tighten both screws to fasten the cover to the body of the Air Pressure Switch Insert the free end of the plastic tubing onto one of the short tubes protruding from the side of the Air Pressure Switch just below the blue knob as follows A The upper tube extending from the baseplate of the Air Pressure Switch is marked with a plus sign on the baseplate Connect the plastic tubing here on the tube when the Air Pressure Switch is being activated by positive air pressure In CE ovens for example the pressure inside the burner blower is positive Figure 3 shows the tubing connection to the tube Connect the plastic tubing to the upper mark tube whenever the Air Pressure Switch is being activated by positive air pressure for example the pressure of an oven s plenum NOTE Step C applies ONLY to PS360WB70 PS360EWB Ovens using burners C The lower tube extending through a notch in the Air Pressur
90. the oven s serial plate Attach on top of existing LPG label on burner o burner motor New label completely covers LPG label Date of conversion TO NATURAL GAS WITH KIT Measured value THIS APPLIANCE HAS BEEN ON Part no of this NO BY WHO ACCEPTS THE RESPONSIBILITY FOR from Section X __ CORRECTNESS OF THIS CONVERSION Kit see chart MODEL NO MAIN BURNER ORIFICE SIZE MANIFOLD PRESSURE on Page 1 INPUT RATI MAXIMUM INLET d 14 W C 34 9mbar Stated on the oven s serial plate 130 Attach completed label in plain See chart on view near serial plate Page 1 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 36856 Gas Conversion Kit for PS360EWB WB70 with Midco Burner Natural Gas to Propane 1 98 fy Middleby Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 847 741 3300 FAX 847 741 4406 Marshall Oven Gas Conversion Kit p n 36856 PS360EWB and PS360WB70 Natural Gas to Propane Installation Instructions WARNING AN This conversion kit is to be installed by a Middleby Marshall Authorized Service Organization in accordance with the manufacturer s instructions and all codes and requirements of the authority having jurisdiction Failure to follow instructions could result in serious injury or property damage The authorized service organization perf
91. the thermocouple out of its mounting hole 3 Disconnect the thermocouple leads Refer to Figure 9 High limit thermocouples are wired directly to the high limit control module The thermocouple s ground wire is connected to the mounting screw for the high limit control module The red and white leads from ALL temperature sens ing thermocouples are joined at capped screw ter minals located inside the left blower motor com partment Leads from these screw terminals con nect to the temperature controller at the front of the oven The ground leads for temperature sensing thermo couples are connected to the chassis ground lug inside the left blower motor compartment Remove and discard the thermocouple Install the new thermocouple into the original mounting hole Fasten it in place with the supplied 6 x 3 8 screws Wire the thermocouple as shown in Figure 9 Use the kit supplied nylon clamp and 10 16 x 3 4 screw to secure the thermocouple leads so that they will clear the shrouds blower belts and pulleys Close the machinery compartment door Replace all shrouds onto the oven Figure 9 Thermocouple Wiring PS555 Temperature sensing thermocouple ground leads attach to ground lug Screw terminals 1 for red leads 1 for white leads 2 total Temperature sensing thermocouple leads red or white Shielded 1 lead to temperature ground lead controller High limit thermocouple leads attach directly
92. thermocouple senses an oven tem perature above 650 F 2 If the signal from the high limit thermocouple is lost An indicator on the Temperature Controller will show a high limit condition This indicator varies by Tempera ture Controller model Referto the instructions for the appropriate Temperature Controller for an illustration and description of this indicator Cooldown NOTE PS200VL series ovens do not include a cooldown feature When the heat and blower Switches are turned OFF the cooldown relay will allow the blowers to remain ON until the oven temperature falls to 200 F 93 C During cooldown the Temperature Controller will con tinue to show the oven temperature SECTION 1 SEQUENCE OF OPERATION ELECTRIC OVEN SEQUENCE OF OPERATION Electrical Supply Most electrically heated ovens operate on a 208 230 380 440V 3 phase 4 wire system The fourth wire is for a 120 V neutral ground This 120 V neutral ground eliminates the need for a control transformer Where a neutral is not available 240 110V transformer is sup plied Door Switch Closing the control cabinet door or machinery com partment door as appropriate for the oven model will close the door switch and allow the oven to operate Note that the electrical systems will still be live if the switch is open although the oven cannot operate The door switch has a bypass position to enable ser vice operation with the door opened When
93. to a normal operating temperature between 200 600 F 93 315 C b Turn the oven on and allow it to heat to 600 F 315 C c After the oven has reached the setpoint temperature set the Thermocouple Source to 700 F 371 C The high limit control is set to open at any temperature in excess of 650 F 343 C This will shut down the oven s heat circuit and illuminate the Reset Switch lamp Set the Thermocouple Source to a temperature setting below 600 F 316 C and depress the Reset Switch This should turn off the Reset Switch lamp and restore heat circuit operation Turn the oven off you replaced a UE type 55 controller with a cooldown circuit you must set the Thermocouple Source to a temperature setting below 200 F 93 C Then wait for the blowers to turn off Press the door safety switch in to reset it to normal Remove the Thermocouple Source from the oven Reattach the thermocouple wires to the high limit control s terminals as follows White wire Red wire Close the machinery compartment and control compartment access panels and fasten them in place The oven is now ready for normal operation Page 5 of 8 SERVICING COMPONENTS SECTION 3 o o tO o c gt e o i 89 58 ef 9 oS 5 2c 7 a xe 5 cg lt D I YOUMS yms OL 18 NS OL
94. to high limit control module Red White db TC TC RESET O SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kits 33984 and 33985 Oven Thermocouple Kit 11 01 5555 Electric and PS555E Temperature sensing thermocouples on these ovens are lo cated on the rear wall High limit thermocouples are lo cated inside the machinery compartment All thermo couples are secured in place by two screws that are in serted through the holes in the thermocouple flange These ovens are equipped with a three lead flanged thermocouple identical to the one in this Kit NOTE FOR HIGH LIMIT THERMOCOUPLES PS555E electric ovens are equipped with a high limit ther mocouple at the front of the oven inside the machinery compartment All other PS555E PS555G and PS570G ovens have a high limit thermocouple installed into the rear wall in the last mounting hole at the exit end of the oven The thermocouple supplied in this Kit can be used to replace ANY of the temperature sensing or high limit ther mocouples on the oven If you will be replacing the high limit thermocouple open the machinery compartment door To replace any other thermocouple first remove the rear shrouds Then remove the cover over the left blower motor This allows access to the thermocouples on the rear wall and to the terminal block inside the blower motor compartment Figure 10 Note tha
95. 009 22174 0009 22174 0009 22174 0009 BYPASS ORIFICE PRO 0 038 0 97mm 0 038 0 97 mm 0 038 0 97 0 0387 0 97 _ 0 0387 0 9 0 03870 97 0 038 0 97mm 62 drill 62 drill 62 drill 62 drill 62 drill 62 drill 62 drill 28092 0018 28092 0018 28092 0018 28092 0018 28092 0019 28092 0018 28092 0018 28092 0018 GAS VALVE SPRING same as PROPANE natural gas NOTE Bypass orifices are used ONLY on ovens equipped with an on off gas regulation system with a solenoid valve These ovens include PS200 series PS310 PS360 PS360WB70 through 3 02 PS314 PS360WB 55705 through 8 00 Ovens equipped with a PID modulated gas system with a modulating valve do not use bypass orifice These ovens include PS200 series PS360EWB PS5708 PS570G 4 02 or later 5555 9 00 or later NOTE Installations at higher altitudes have a lower ambient air pressure that disrupts the air fuel mixture To correct this problem smaller gas orifices are required Ageneral rule is a 4 reduction for each 1000 ft 305m above sea level Refer to the chart in the Appendices section page 135 for a listing of orifice sizes showing this reduction 91 SECTION 3 SERVICING COMPONENTS Component Identification 1 Burner type Middleby ovens are equipped with one of two main burner designs Details of these burners are provided below 1 Air shutter Main gas line Mid
96. 0V on off mode only Used on PS200VL series ovens only PS200VL series ovens equipped with this Temperature Controller do not have a cooldown feature and use a separate high limit con trol module P N 28071 0027 C Digital Temperature Controller with blue plastic face plate 120V on off mode only P N 28071 0028 D Digital Temperature Controller with gray rubber face plate and buttons with text 120V on off mode only P N 28071 0028 E Digital Temperature Controller with gray rubber face plate and buttons with symbols 120V on off mode only SECTION 3 SERVICING COMPONENTS shown are no longer available and part numbers are pro vided for reference only Servicing these units is beyond the scope of this manual If one of these controllers is in need of service we recommend simply installing a current unit P N 46837 included in Kit P N 47321 P N 30871 E Digital Temperature Controller with gray rubber face plate and buttons with symbols 208 240V on off mode only Used on early PS360WB70 and some CE oven models P N 32571 E Digital Temperature Controller with gray rubber face plate and buttons with symbols 208 240V PID mode only Used on early PS360EWB P N 36021 F Digital Temperature Controller with gray face plate steel trim on edges 120 240V selectable on off or PID modes P N 36056 G Service Kit P N 36939 Digital Temperature Controller with black plastic face plate 120 240V s
97. 2 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 42810 0121 Combination Gas Valve 1 92 1 Mount gas contro 07 907 n any direc tion from the upright position of the gaa contol knob 2 Mount the gas so gas flow is in the direction of arrow on the bottom of the gas control 3 Apply amoderate amount of good quality pipe compound do not use te lon tapa to pipa only leaving the last two nd threads bare On propane installations use compound resistant lo propane gas 4 Remove seals over gas control inlet and Figure 1 Top View Of Gas Control outlet 5 Connect pipe to gas control and outiet Use wrench on the square ends o the gas control Insert pipe maximum of 1 2 Into contral valve Distortion or malfunction may result if the pipe is Inserted too deeply Into the gas oonirol PILOT GAS TUBING INSTALLATION 1 Cut tube to desired length Square off and remove burs from end of tubing both inside and outside 2 Bend tube as necessary for routing to pilot burner Do not make sharp banda or deform the tubing Do not bend tubing at gas control or pilot burner aliar compression fitting has bean tightened as this may gas leakage at the connection 3 Unscrew compreasion hitting from the plot outlet of the gas control Silp tha compression fitting over the tubing and sikte out of the way 4 Push tubing Into the pot outlet It bottoms While holding tubing
98. 240V elements are also used on ovens with 416V 480V supply connected in se ries e 380V elements are used for ovens with a 380V supply All heaters are connected in Delta e Each element is stainless clad and has a 4 7 8 124mm cold unheated end next to the connect ing leg Individual element electrical data Volts Watts Ohms Connection 208V 1350W 320 Parallel 220V 4270 Parallel 230V 1239W 4270 Parallel 240V 1350W 4270 Parallel 380V 1350W 1070 Parallel 416V 1013W 4270 Series 480V 1350W 4270 Series Checking the Heating Elements The most common problems encountered with electric heaters are Open or bad connections Open shorted or grounded heating elements To troubleshoot the heating elements disconnect all leads from ALL of the elements in the bank Then check each element with a digital multimeter set to Figure 82 Spacer brackets SECTION 3 SERVICING COMPONENTS Ohms 0 Correct ratings are shown in the table in the preceding section Zero reading on the ohm scale indicates an open or shorted element It is also possible to check for an open element using an ampmeter Any current through the element indi cates that the element is not open Changing Heating Elements NOTE Wires going from the mercury contactors to the heating elements are rated at 12 gauge TAGT 482 F 250 C DO NOT under any circumstances use a wire of lesser rating or quality NOTE l
99. 30 Fuse 50A class T 31463 Relay solid state 75A 35018 Circuit breaker block 50A 3 pole Supply Ovens have a 208V 220 240V 380V 416V or 480VAC electrical supply The control current of the oven oper ates at 110V single phase If the oven was specified for a 3 wire system it was supplied with an optional control transformer to step the 3 phase current down for the control circuit If the oven was specified for a 4 wire system the 4th neutral wire is utilized to split 2 of the 3 incoming 3 phase legs and obtain a separate 110V circuit Most export ovens are supplied with a stepdown transformer for the 110V control voltage Figure 77 PS200 electric current with solid state relays and circuit breaker blocks Circuit breaker block with 50A breakers relay Heater specifications e PS 200 series electric ovens use six individual heat ing elements e 208 elements are used for ovens with a 208V supply 240 volt elements are used for ovens with 220 230 or 240V supply 240V elements are also used on ovens with a 416V or 480V supply connected in se ries e 380V elements are used for ovens with a 380V supply All heaters are connected in Delta Each heating element is stainless clad and has a 3 76mm cold unheated end next to the connect ing leg Individual element electrical data Volts Watts Ohms Connection 208V 4500W 9 60 Parallel 220V 3781W 12 80 Parallel 230V 4133W 1280 Parallel
100. 32 Align bearing set screws with flats on shaft but do not tighten set screws at this time 10 Insert fan shaft alignment tool Item 15 into back wall as shown in Figure 31 NOTE The bracket assembly is designed for slight up and down and right to left movement to attain free shaft rotation when the shaft alignment tool is in place Once free shaft rotation is achieved tighten all eight bracket screws Item 2 11 Tighten rear flange bearing block screws Item 11 then front flange bearing block screws 12 Remove shaft alignment tool then recheck fan shaft for free rotation 13 Install pulley Item 8 on fan shaft and position fan shaft perthe dimensions shown in Figure 32 Align the two flats per bearing which are machined on fan shaft for the bearing set screws Use High Temperature Loctite RC 620 on bearing set screws and then tighten set screws Recheck fan shaft for free rotation 14 Apply anti seize compound on fan shaft before in stalling fan blade Item 13 Position fan blade per dimension shown in Figure 32 15 Apply High Temperature Loctite Type RC 620 to fan blade set screws NOTE Tighten the two set screws on fan blade per the following sequence when viewing fan blade from front first the screw at the 12 00 position then the screw at the 3 00 position 16 Recheck fan shaft rotation before installing back wall to oven cavity NOTE Apply anti seize compound MM P N 17110 0017 to all 12
101. 36856 Gas Conversion Kit for PS360EWB WB70 with Midco Burner Natural Gas to Propane 1 98 131 Instructions for Service Kit 36863 Gas Conversion Kit for PS360EWB WB70 with Midco Burner Propane to Natural Gas 1 98 135 Equivalent Orifice Sizes at High Altitudes 4 02 139 Electric Oven Heating System A PS200 series PS310 360 series ovens 3PS555 ovens D Electric Oven Mercury Contactor Replacement 146 Section 4 Electrical Wiring 149 Component 149 A Temperature 149 B Ignition Modules 150 PS200 series Ovens 2 4 4 151 ll 5310 360 OVENS 160 PS555 570 series OVENS 166 Section 5 Reference 25 point preventative maintenance checklist Fractional inches to decimal and millimeter equivalents 173 Decimal equivalents of drill 2 173 General conversion factors
102. 4 and 33985 Oven Thermocouple Kit 11 01 Figure 11 Location of New Thermocouple Mounting Holes PS570 PS570S High limit thermocouple High limit thermocouple position for ovens with position for ovens with LEFT TO RIGHT conveyors Thermocouple positions RIGHT TO LEFT conveyors for non Pizza Hut Tricon ovens Thermocouple positions for Pizza Hut Tricon ovens CO 127mm gt K 3 1 2 89mm 552 lt _ 512 7164 dig N 140mm 7 gt 3 8 9 5 1 1 00 3 8 yf w 2 N 11 32 dia K 5 1 2 7 140 Figure 12 Thermocouple Wiring PS570 and PS570S early after thermocouple update Left to Right Conveyor White Red Red White Ground Red White Right temp temp temp temp leads all hi lim hi lim Terminal ea d Block Left Ground Terminal lead Block m Ol Sols temperature ground wire controller New chassis 1 temperature To high limit controller control module Figure 12b Thermocouple Wiring PS570 and PS570S early after thermocouple update Right to Left Conveyor Left White Red Ground White Red Red White G
103. 68 Back Wall Assembly 11 1 27399 0003 Blower Fan 16 Dia 2 16 21216 0001 Screw Hex Cap SS 3 8 16x1 12 4 21419 0004 Flat Washer 3 8 SS Special 3 16 21422 0001 Lock Washer Split 3 8 13 1 37900 0106 Fan Shaft Alignment Tool 4 12 21416 0001 Flat Washer SS 3 8 Also available 5 1 37900 0101 Bracket Indirect Drive 49810 0018 Fan Shaft Service Kit 6 1 35900 0232 Shaft Fan Drive Includes Qty 2 of Item 9 and Qty 1 ea 7 1 22230 0073 Pulley 5 8 Bore of Items 6 and 13 8 1 21651 0008 Square Key 3 16 49810 0021 Fan Shaft Upgrade Kit 9 2 22072 0025 Pillow Block Bearing 5 8 Bore Includes parts and instructions to up date early style fan shaft assembly to 10 4 21422 0001 Lock Washer Split 1 4 the current version shown here 73 SECTION 3 SERVICING COMPONENTS B PS360 series ovens All PS360 series ovens are equipped with two blower motors Allgas ovens have motors rated at 230V single phase All electric ovens built before 8 02 have three phase motors All electric ovens built 8 02 or later that operate on a supply voltage of 208 240V have single phase motors Allelectric ovens built 8 02 or laterthat operate on supply voltages above 240V have three phase motors Blower motors are protected by A built in thermal overload protection device For ovens with single phase blower motors Two fuses Fuse location is shown in Figure 35 For ovens with three
104. 708 ovens All of these ovens use a 120V burner blower motor Most units equipped with the 120V burner blower motor also use the angled flame target The round flame target is used on PS200 series ovens built 4 02 or later PS360EWB and PS360WB70 ovens equipped with the Wayne burner system PS555 PS570G ovens All of these ovens use a 208 240V burner blower motor All ovens equipped with the line voltage burner blower motor use the round flame target Figure 65 Flame targets ou Round target Angled target 93 _ SECTION 3 SERVICING COMPONENTS 3 Pilot and Proof of Pilot Flame Figure 66 Rectification Flame structure With standing pilots heat is a necessary ingredient for proper thermocouple opera tion But this is not the case with IIDS Intermittent Ignition Device Systems when flame conduction or rectification is used To better understand the principles of flame conduction and rectification we must first understand the structure of a gas flame See Figure 66 With the proper air gas ratio to give a blue pilot flame three zones exist Zone 1 An inner fuel rich cone that will not burn be cause excess fuel is present Zone 2 Around the inner fuel rich cone is a blue enve lope In this area is a mixture of vapor from the fuel rich inner cone and the secondary or surrounding air This is where combustion occurs Zone 3 Outside the blue envelope is a third zone that
105. 7384 0014 22450 0230 27170 0263 46606 46658 46451 46602 PS570 570S Split Belt High Speed New Motor part numbers shown in this table are kits that include both the motor and the new pickup clamp SECTION 3 SERVICING COMPONENTS Appendix DIP switch settings for Conveyor Speed Controller with Digital Display P N 37337 4 02 OFF ON E H OFF a E E H a 8SL9OGVECHL 8SL9OGVTVECHL 8SLZ9OGVECHL 8SLZ9OGVECL 200 SERIES 1350 1 MTR 3 30 min 1400 1 MTR 3 30 min 31458 600 1 MTR 1 10 8SL9OGVECHL 8BLOGVTECHL 98 9S8vt c l 536 9 3 RPM 3 30 570 1350 1 MTR 4 30 30 570 311 1 MTR 1 30 10 TEMPERATURE CONTROLLER The Temperature Controller is used to set and control the oven temperature Depending on the oven model the con troller has several functions Ongasovens with On Off gas valve operation the tem perature controller opens and closes the high flame solenoid This allows 10096 or 096 gas flow to the burner in response for the need for heat to maintain the set point temperature The temperature controller has no effect on the low flame bypass or oven ignition Forthis operating mode the temperature controller is set to the On Off Mode as described in the Kit instructions Ongas ovens with modulated gas valve PID opera ti
106. 8 240V main blower motor and control circuit 208 240V 50 60 Hz 1 Ph 2 pole 3 wire supply 2 hot 1 ground SINVHOVIO ONISIM TVOIH LO3 T3 NOLLO3S 59 A DISTRIBUTION BLOCK 19 1813 515181 1 1 mo i 1 n9 Q exe D 1 4 1 a 1 1 4 1 LI END T BLK Or lt 12 12 12 12 12 12 12 12 NOTES USE 75 C WIRE ONLY ALL WIRES ARE TO BE 18 AWG UNLESS OTHERWISE SPECIFIED USE COPPER WIRE ONLY MAXIMUM SUPPLY CIRCUIT PROTECTIVE DEVICE 100 AMPS MINIMUM SUPPLY CONDUCTOR AMPACITY 85 AMPS WD LABEL 22500 0125 WHT 515 m F3 LPS CONVEYOR z 4 SWITCH PINK WHI 3 274 BLK C4 1 E z BLOWER SWITCH 3 i COOLING FAN COOLING FAN m em MOTOR 2 HEAT SWITCH A 2 1 HEATERS Sot PS360 series electric oven 208 240V main blower motor and heating elements 120V control circuit 208 240V 50 60 Hz 3 Ph 4 pole 5 wire supply 3 hot 1 neutral 1 ground COIL MTR BLWR SINVHOVIO ONISIM TVOIH LO3T13 NOLLO3S 99 NOTE All wires to 208 240V be No 18 AWG 50 60 HZ American Wire Gauge 2 2 6 gm l Ground 22 5 elo 16 wht 16 blk x Y x g 25 2 in LEL J Left Rear a L Safety
107. 88 28091 0017 Pilot 27170 0017 Manual shutoff pressure valve 1 2 Bypass line tap Relay 27170 0016 23115 0009 1 4 aluminum tubing 30185 15125 0002 per foot Figure 59 PS570G or PS555 gas train Air shutter 42810 0087 Pilot line M420 modulating 1 4 aluminum tubing valve 1 2 15125 0002 41647 Burner blower foot per foot and motor assy Combination gas control valve 1 2 208 240V 45688 27170 0287 1 2 union 23051 0003 Air tube silicone rubber 22450 0297 per foot TO POSITIVE SIDE OF AIR Flexible air hose SWITCH 22450 0255 Manual shutoff valve 1 2 Pilot pressure tap 23115 0009 30185 90 SECTION 3 SERVICING COMPONENTS Figure 60 Wayne burner exploded view Pilot ignitor assembly 42810 0117 Pilot shield Venturi 27170 0204 Wtih angled flame target Burner blower and motor assy 120V 27170 0011 208 240V 27170 0287 27170 0223 With round flame target Air shutter 42810 0087 Pilot orifice Main orifice See chart below See chart below E e N Pitot tube assembly LZ for use with 208 4 240V motors 42400 0640 B Part Number Reference Gas Orifices and Gas Conversion Kits PS360WB70 EWB PS360WB70 EWB PS200 PS220 224 PS310 314 360 PS360WB Midco burner Wayne burner PS555 PS570S PS570G Description 42810 0125 42810 0126 42810 0120 42810 0127 36863 44664 43061 42810 0127 GAS CONVERSION KIT PROPANE TO NATURAL 22176
108. 9 0JjUO 9 1 1 5 15199 40 Aejdsiq 111 07 104 395 4 56 5 epolN 7 of 10 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 47321 Digital Temperature Controller Kit 2 02 Diagnostic Error Messages The controller runs background tests during normal operation If any problems occur during the tests an error message flashes in the display A listing of these diagnostic error messages is shown below D I Flashes on the display alter nating with the temperature indicating that the internal di agnostic test has failed 11 2 The oven temperature has not reached 200 F 93 C within 15 minutes of startup On gas ovens this is usually a result of the burner not light ing Caused by an open in the thermocouple circuit L Polarity of the thermocouple leads is reversed Turn the Blower Switch HEAT Switch for PS536 ovens with the two switch configuration OFF for 2 minutes 2 Turn the Blower Switch or HEAT Switch as per Step 1 ON If necessary repeat Steps 1 and 2 up to two additional times 4 Ifthe problem does not clear after 3 attempts replace the controller Turn the Blower Switch HEAT Switch for PS536 ovens with the two switch configur
109. 97mm 0 038 0 97mm 3162 drill 62 drill 62 drill 62 drill 62 drill 62 drill 28092 0018 KIT GAS CONTROL VALVE SPRING PROPANE 22500 0065 LABEL PROPANE RED 22500 0123 LABEL GAS CONVERSION 22501 0007 TAG GAS CONTROL CONVERSION 88210 0069 INSTRUCTIONS ENGLISH page 1 7 NOTE The bypass orifice is not used if the oven is equipped with a modulating gas valve These ovens include PS360EWB all PS555 all 55705 units produced 4 00 or later For additional information refer to Part of these instructions Bypass Orifice Conversion pagina IMPORTANT THIS CONVERSION KIT IS INTENDED FORAGA CGA AND CSA APPROVED MIDDLEBY MARSHALL GAS FIRED OVENS OPERATING AT ALTITUDES UP 5000 FT 1524m FOR OVENS INSTALLED AT ALTITUDES ABOVE 5000 FT 1524m CONSULT THE FAC TORY BEFORE INSTALLING THIS KIT THIS KIT MAY NOT BE USED WITH CE APPROVED MIDDLEBY MARSHALL OVENS FOR THESE OVENS FOLLOW THE GAS CONVERSION INSTRUCTIONS IN THE NSTAL LATION SECTION OF THE 5 OWNER S OPERATING AND INSTALLATION MANUAL ESPANOL WARNING THIS CONVERSION KIT IS TO BE INSTALLED BY AMIDDLEBY MARSHALL AUTHORIZED SERVICE AGENT IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS AND ALL CODES AND REQUIREMENTS OF THEAUTHORITY HAVING JURISDICTION FAILURE TO FOLLOW INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR PROPERTY DAMAGE THEAUTHORIZED SERVICE AGENT PERFORMING THIS WORKASSUMES RESPONSI
110. AX 847 741 4406 24 Hour Service Hotline 800 238 8444 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 WARNING DISCONNECT THE OVEN FROM ITS ELECTRICAL POWER SUPPLY BEFORE SERVICING 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 other than your Middleby Marshall Authorized Service Agent may void your warranty NOTICE Using any parts other than 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 TABLE OF CONTENTS Section 1 Sequence of Operation 4 F Initial Troubleshooting Gas Oven Sequence of Operation 4 Conveyor Control Pickup Electric Oven Sequence of Operation 6 H Conveyor Motor Replacing the Magnetic Pickup Section 2 Air Flow and Heat Transfer 7 J Unshielded
111. Analog Temperature Controller Remove AND RETAIN the screw that holds the thermo Shielded couple in place on the rear wall White Red ground lead Disconnect the thermocouple leads Carefully thread the wiring out of the oven and discard the thermocouple 5 6 7 Slide the new thermocouple into the mounting tube until GIGIG the flange is seated firmly on the back wall of the oven G 5 6 7 Fasten the thermocouple to the back wall of the oven using the original mounting screw Then perform Steps 6 8 of the preceding section to wire the thermocouple 9 10 11 12 13 14 15 16 lt 10 11 12 13 14 15 16 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kits 33984 and 33985 Oven Thermocouple Kit 11 01 PS360 Series front mounted thermocouple Figure 5 NIE Thermocouple Installation PS360 Series inside the machinery compartment Machinery Compartment These thermocouples are mounted in a tube that extends diagonally up and into the plenum chamber They are se cured in place by a set screw located on the mounting tube and by a bead of high temperature silicone around Thermocouple the end of the shaft The new thermocouple will be held in place in the same High temperature manner except that the silicone should be applied so that s
112. BILITY FOR THIS CONVERSION WARNING BEFORE PERFORMING ANY SERVICE WORK THE ELECTRICAL POWER SUPPLY AND THE GAS SUP PLY MUST BE TURNED OFF P N 88210 0069 Rev C V1 8 00 119 SECTION 3 SERVICING COMPONENTS Appendix Instructions for All Gas Conversion Kits for Ovens with Wayne Burner Natural Gas to Propane 8 00 Typical PS200 series gas train configuration Solenoid Pilot line Combination gas control valve He safety regulator E VI x Burner Pilot pressure tap pilot tee 5 19 9 5 LEN Modulating gas blower valve if so equipped Solenoid valve if so equipped Combination gas control valve safety regulator Burner Gas pipe shutoff valve Modulating gas Burner valve if so blower equipped Solenoid valve if so equipped Combination gas control valve safety regulator Pilot pressure Gas pipe tap pilot tee shutoff valve union 120 SECTION 3 SERVICING COMPONENTS Appendix Instructions for All Gas Conversion Kits for Ovens with Wayne Burner Natural Gas to Propane 8 00 PREPARATION AND DISASSEMBLY Turn off the electric power supply to the oven Turn off the gas supply at the service valve behind the oven Open the machinery compartment door Open the union in the gas supply line The union is located on the inlet side of the combination gas control valve See Figure 1 Unscrew the four hex screws that hold the ven
113. Blower Wheel Orientation Orientation SECTION 2 AIR FLOW AND HEAT TRANSFER B PS360 series ovens PS360 series ovens feature two blower motors A blower wheel is fastened onto the end of the motor shaft In order to adjust the amount and speed of heated air that is directed by the blower wheels it is necessary to change the size of the wheels and or change the speed of the motor See Figure 1 Each PS360 series oven model has a specific combi nation of blower motor and blower wheel Field modifi cations to these approved combinations are not per mitted unless under the specific directions of the Middleby Technical Service Department Any changes to convection air delivery MUST be made using the air fingers C PS555 570 series ovens PS555 570 series ovens have one blower motor mounted inside each of the end compartments of the oven with a pulley on the end of the motor shaft The oven has two blower wheels a belt connects each motor pulley to a pulley on the end of one of the blower wheel shafts The air velocity can be changed by using a larger or smaller pulley on the motor shaft and chang ing the length of the belt to match the new pulley See Figure 1 Some customers have a specific belt pulley combina tion approved by Middleby Marshall while others use a standard configuration Field modifications to these approved combinations are not permitted unless under the specific directions of the Middleby Technic
114. C Gauge Series PS500 Ovens 110 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 30185 Pilot Tee 3 94 C PILOT LIGHT CHECK 1 Cycle oven back onto high flame and check burner flame for proper color Natura appears soft biue with orange tips and propane gas appears orange The shutter plate cn ihe burner Blower motor is typically set at PS200 Series 1 16 to 3 32 PS300 Series 1 8 to 3 15 PS500 Series 1 8 to 1 4 Each installation can vary Adjust the shutter plate until the color is correct Aiso check for proper microamp readings Refer to Technical Manual P N 88210 0019 Section 2 Tum burner off by cycling the burner heat switch momentarily two or three times 10 check for proper reignition If difficult lighting or burner outage occurs go to Step 3 If reignition is satisiactory then skip to Step 4 f burner is difficult to light or goes out intermittently check for proper microamp adjustment of pilot using Technical Manual P N 88210 0019 Section 2 Recheck pilot pressure on low flame to be sure it is adjusted within the correct parameters listed in Step B 4 of these instructions off the gas flow to burner by turning heat switch to the OFF position Remove water column gauge and install tee plug and check for leaks For further assistance with any portion of these instructions call the Technical Service Hotline at 1 800 238 8444 SECTION 3 SERVI
115. C minimum rating as a replacement Excessive temperature at the ceramic flame rod insu lator can also permit electrical leakage to ground Examine the flame rod and mounting bracket and cor rect if it is bent out of position Replace the ignitor sensor if the insulator is cracked Ignition Module Flame Sensor Circuit Test The ignition module provides AC power to the ignitor sensor which the pilot burner flame rectifies to direct current DC If the flame signal back to the control module is not at least 2 0 uA DC the system will lock out The output of the flame sensing circuit cannot be checked directly so check the flame sensing circuit indirectly by checking the flame sensing current form the ignitor sensor to the control module as follows a Connect a ampmeter multimeter set to read DC microamps pA in series with the flame signal ground wire Disconnect the ground wire at the control module Connect the red positive lead of the meterto the free end of the ground wire Con nect the black negative meter lead to the ground terminal on the ignition module 101 SECTION 3 SERVICING COMPONENTS b Restartthe system and read the meter The flame sensor current must be at least 2 0 pA and the reading must be steady If the reading is below 2 0 or if the reading is unsteady check the pilot flame and electrical connections as described above Also replace the ignitor sensor if the ce ramic insulator is c
116. CING COMPONENTS Appendix Instructions for Service Kit 42810 0121 Combination Gas Valve 1 92 7 Middleby Marshall MIDDLEBY COMPANY intermittent Pilot Combination Gas Control Kit Kit Number 42810 0121 installation instructions WARNING FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH Do Not attempt to use a gas control set for natural gas on propane gas or gas control set for propane gas on natural gas IMPORTANT These gas controls are ehipped with protective seats over Inlet and outlet tappings Do Not remove seals until ready to connect piping WARNING FIRE OR EXPLOSION HAZARD CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH Do Not dissssembte the gae control It contains no replaceable componente Attempted disassembly or repair may damage the gas control The following instructions describe the instalation of the Middleby Marshall gas control kit MMP N 42810 0121 which Is the replacement for the disoon tinued gas contro MMP N 28092 0013 Tho new gas control kitconsists of four 4 parts 28092 0017 Gas Control 33300 0228 Pilot Tube 23070 0055 Compression Nut w Sleeve 88210 0068 Instruction Sheet The new contro will fit existing applications of the discontinued control however due to the new pilot outlet location Itis necessary to Install the longer pllot tube supplied in the kit 1802 Middleby Marshall Part Number 68210 0068 1 92 11
117. CONVEYOR SPEED an CONVEYOR CONTROLMODULE SENSOR DRIVE MOTOR T E BLK DOOR Z SAFETY 6 SWITCH REAR is WHITE BLUE SAFETY CONVEYOR T HIGH LIMIT D SWITCHES RESET SWITCH 4 RIGHT 4 4 ND LAMP x SILVER M2 Tp SILVER AA e BLACK 22 04 2 BROWN mum HIGH LIMIT CONTROL BROWN BROWN L D PURPLE RED punpLE 4 4 nED BLK BLOWER me pack BLK BLACK COOLING FAN LEFT HEAT BRO IM WHITE COOLING FAN RIGHT PRESSURE E COOLDOWN omom e COIL BLOWER MOTOR SWHCHHE N ORANGE BLACK N O 200 F 93 C ME pers II EM 19 SOLENOID PEL E VALVE TERMINALS RANI YELLOW HIGH LIMIT NO me 650 343 C RELAY 4 3 NO 6 1 o jede PRESSURE BLACK 5 1 SWITCH 2 NO BLACK IGNITION WHITE __ MODULE TEMPERATURE CONTROLLER es BURNER BLOWER PILOT MOTOR WITH BURNER Q CENTRIFUGAL SWITCH SENSOR yo Gag GROUND zu CONTROL oe VALVE PILOT em WHITE OUTLET THERMOCOUPLE HIGH FLAME m SOLENOID VALVE PS570 or PS570S gas oven with solenoid valve and digital temp control 208 240V main blower motor 120V control circuit 208 240V 50 60 Hz 1 Ph 3 pole 4 wire supply 2 hot 1 neutral 1 ground SINVHOVIO ONISIM 0819 N
118. E EXISTING CONTROLLER IS P N 36056 OR P N 46837 shown in Figure 1G the new controller can be installed directly into the existing sleeve as follows Loosenthe Phillips screw at the bottom center of the faceplate Pullthe old controller out of the sleeve Skip ahead to the Jumper Setting section of these instructions on Page 6 to set up the new controller After the jumper is configured the new controller can be installed directly into the existing sleeve FTHE EXISTING CONTROLLER IS OF ANY OTHER TYPE the sleeve will have to be replaced with the one included in this Kit Continue on to Step 2 in this section Access the back of the existing temperature controller Tag each wire that connects to the controller with its terminal number These numbers will be used later to wire the new controller Disconnect all wires from the terminals on the temperature controller Be sure to retain any jumpers that are removed Removethe controller and sleeve from the oven as follows Foranalog controllers P Ns 28071 0012 and 28071 0018 Fig 1A remove the two bracket screws on the back of the control Then remove the bracket Pull the controller and sleeve out through the front of the oven panel For all other controllers remove the two screws and brackets that hold the controller in place Then pull the controller and sleeve out through the front of the panel Page 3 of 10 SECTION 3 SERVICING COMPONENTS Appendix Instructi
119. ER S L6 37000 0577 WLOMT PLATE INNER COL W DAM 42410 0184 ASSY MANIFOLD BAFFLE ALUZ 35210 0538 PLATE FULL BLANK ALUZ 31257 REV J CONFIG FINGER PS570S STD 35210 0535 PLATE BLANK PRTL 2 75 UPR 570 35210 0590 PLATE BLANK PARTIAL ALZ LWR570 RT TO LT MIRROR IMAGE OF FINGER ARRANGEMENT MOTOR PULLEY P N 44977 BELT SIZE BX67 PAN 46452 RPM 1780 NOTE All ovens use a chart of this type inside the machinery compartment Changes to the air finger configuration after oven installation MAY NOT BE INDICATED SECTION 2 AIR FLOW AND HEAT TRANSFER To perform the test bake 1 Select identical pans for the test Choose the pans based on the width of the conveyor you should space the pans in line completely across the conveyor with out having them touch each other For instance fora 32 813mm wide conveyor you could use three 10 254mm pans or two 15 381mm pans You will need enough pans to have three complete rows This eliminates the possibility of a single row distorting the results If necessary the test can be run with only 1 row of pans but the results are not as reliable For a pancake batter test mix the pancake batter as instructed by the manufacturer Pour the batter EVENLY into the test pans to a depth of 1 4 6mm You may use any type of pancake mix that is available AS LON
120. EX BOLTS that hold the bearings to their mounting brackets Leaving the bearings loose allows the pulleys to be aligned Next check the alignment of the pulleys using a cord as shown in Figure 48 Reposition the bearings as required to align the blower shaft then tighten the hex bolts to hold the shaft in place Replace the belts and rear shrouds after the pulleys are properly aligned Loosen bolts to reposition motor and adjust belt tension Cord must touch sheaves at four points indicated by arrows 79 SECTION 3 SERVICING COMPONENTS VI BLOWER MOTOR CENTRIFUGAL SAFETY SWITCH PS360 SERIES Middleby ovens have a safety feature that prevents the burner heating elements from activating if the blower s are not in operation On PS360 series ovens this feature is controlled by a centrifugal switch mounted inside each blower motor If either motor is not operating the burner heating elements cannot activate The centrifugal switch is a normally closed NC limit switch mounted inside the rear of each blower motor See Figure 49 When the motor is not running the centrifugal switch weight holds the switch open As the motor reaches full speed the weight moves away from the switch permitting the contacts to close When the switch contacts of BOTH blower motors are closed the heat circuit is completed allowingthe burner heating elements to activate If a blower motor is not operating the
121. G AS YOU USE THE SAME TYPE THROUGH OUT THE TEST For a dough test have the customer make up a thin crust dough in each pan The dough should be of a consistent thickness in each pan and should be no thicker than 1 4 6mm Thicker doughs will provide too great a cushion and will distort the test results Place the pans side by side on the conveyor The front and rear edges of the pans should be aligned so that it is easier to see if there is a front to back bake prob lem DO NOT stagger the rows of pans diagonally Also check that the pans do not touch each other this can transfer heat to the test product and distort the results Run the products through the conveyor at the customer s normal bake time and temperature settings Read the results of the test Each pan of product should have the same coloration If you used pancake batter the sugar in the mix will brown very rapidly if over baked This highlights an out of balance oven If the product lightens or darkens slightly from front to back in only one row there is probably not a significant front to back bake problem If the product is notice ably lighter or darker at the front or back in ALL of the rows of pans there is a front to back bake problem See Figure 7 Also remember that consistently uneven baking on the top of the product may indicate a problem with the upper air fingers Likewise consistently uneven bak ing on the bottom of the product may indic
122. ICING COMPONENTS SECTION 3 N N i gt O 5 g 5 E D m 1 N lt o o c 5 gt o 1 X lt s jun 10 Julod jas pue ueewjeq ysey iim Aejdsiq Buiuuni si gt 4 4907 10 195 49 JO4JUOD y eu si ON J julod 195 eq ISNIN LNVLISHOdNI eunj ojne Meu uny Buiunj ojne diys Joejes oj pabueyo 99 JOUUBD 1 Buiunj ojne 158 Aq pue 404 yoojun lt eun ojny uns LI 1 mo LILILI moe 0jny 4 20 Julog 195 suunjel S eunj ojne ue uuojyied pinoys INVL3 OdMI eunj ojne
123. IN ANY TUBE ENVELOPE DENOTES GAS DOT IN ANY TUBE ENVELOPE DENOTES GAS NEON as I IMG SEMICONDUCTORS RECTIFIER RECTIFIER ARC SUPPRESSORS DIODE BRIDGE LIST VALUES OF RES AND CAP 178 SECTION 5 REFERENCE Common electrical wiring diagram symbols continued MISCELLANEOUS TERMINAL BLOCK LOCATION OF RELAY CONTACTS CLAMP 2 3 4 NUMBERS IN PARENTHESES DESIGNATE THE LOCATION OF RELAY CONTACTS A LINE BENEATH A NUMBER SIGNIFIES A NORMALLY CLOSED CONTACT 179 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 in the industry 2002 Middleby Marshall Inc V Middleby 772 Marshall is a registered trademark of Middleby Marshall Inc All rights reserved Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 847 741 3300 FAX 847 741 4406 24 Hour Service Hotline 800 238 8444 180
124. IO W 5 REAR 09 ed 0 6 CONTROL SWITCH D C MOTOR tt mie PICK UP 9 O d poor 0 1 SWITCH ER Y BK 16 CONVEYOR SWITCH 8 3 4 8A 8A oe BLOWER SWITCH z 3 19 30 59 130 9 110 1 COOL DOWN Q 65 200 82 9 SWITCH i a a c e A ALL HEATERS WIRES 12 HEATERS PS200 series electric oven export version 208 240V main blower motor and heating elements 120V control circuit NOTE j ALL WIRES ARE TO NO 18 AWG UNLESS OTHERWISE SPECIFIED 2 WD LABEL P N 37855 220 240V 50 60 Hz 3 Ph 3 pole 4 wire supply 3 hot 1 ground SINVHOVIO ONISIM 0819 NOLLO3S 091 3 NOTE All wires are to use in split bell applications only 208 d be 18 AWG unless SG RE E 21 50 60 HZ otherwise specified D C Control Pickup 5 y ge M 4M AC SP SIG 45V Door Switch 5 up DPST 2 N O wht E B re B red D C Motor Pick u D C Control p M iM AD SP COM SIG 15V x JE E 3 bik red Conveyor wht E Switch 45 pink pink wht Light Conv Sw brn wht Light M1 Micro M2 x Blwr Sw Swich brn wht Cooling Fan n 5 5 d 5 5 Cooldown Ci Coil Blwr Mtr 180
125. ITOR BRACKET Old Style 0 70 NOTE NEW POSITION OF HOLES ON NEW STYLE PILOTAGNITOR BRACKET 107 D RIPTION PILOT IGNITOR PILOT IGNITOR BRACKET PILOTAGNITOR REPLACEMENT INSTRUCTIONS SCREW 10 32 x 1 47 PILOT SHIELD VENTURI MM P N 88210 0067 P 7 91 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 30185 Pilot Tee 3 94 LY Middleby 72778 Marshall A MIDDLEBY COMPANY INSTALLATION INSTRUCTIONS PILOT TEE ON PACESETTER OVENS KIT P N 30185 Kit Contains Branch Tee P N 30001 Branch Plug P N 30002 installation Instructions P N 30184 Tools Required Middieby Marshall Technical Manual PN 88210 0019 DC Micro amp Meter Water Column Gauge do not use a dial type meter Aluminum Tube Cutter Soap Soiution For Gas Leak Test Standard Tools of the Trade open end wrench set screw driver set etc Middleby Marshall Inc 1400 Toastmaster Drive Elgin IL 60120 708 741 3300 FAX 708 741 4406 Middleby Corporation Service Hotline 1 800 238 8444 Pari 30184 1994 Middieby Marshall inc P3 94 108 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 30185 Pilot Tee 3 94 INSTALLATION INSTRUCTION PILOT TEE KIT P N 30185 A INSTALLATION OF TEE AND PLUG KIT P N 30185 IMPORTANT BEFORE ATTEMPTING TO INSTALL THIS KIT READ THESE INSTRUCTIONS THOR OUGHLY TURN OFF GAS AND MAIN POWER TO OVEN BEFORE INSTALLING THIS KIT 1 Remove pilot lin
126. LVE To GasControl Pilot Outlet eT Vave Teminas PRESENT STYLE IGNITION 2 Burner 3 d with Ignitor Pilot EARLY STYLE Sensa Bumer CONTROL VALVE Grd GasControl Pilot LSL n NOTE All wires are to use in split belt applications only a es a 4 be 18 AWG unless Bi 1 o T s S 208 240 otherwise specified D C Motor Pick up 9 50 60 HZ 4M SP COM SIG 45V bik 79 al Switch Eu E dL s Lr a Pick D C Control oe 911 Door Interlock n 4 Switch bk 16 M 4M Ap AC SP COM SIG45V bik Conveyor wht bik Light 2 4 2 Cow Sw Q O Pressure Light Switch Hoa Cooldown Blwr Sw Salen 180 F Hi Limit 2 9 S 650 F 44215 16 of 5 Controller 1 59 79 19 20 Skt A 2 0 ht Centrifugal Sensor mg 7 gt lt i 6 High Flame Switch To GasControl 2 1 8 Pilot Outlet Light Heat Sw PS200 series gas oven with solenoid valve and analog temp control 208 240V main blower motor 120V control circuit 208 240V 50 60 Hz 1 Ph 3 pole 4 wire supply 2 hot 1 neutral 1 ground SN3AO 531435 0025
127. ND the gas supply MUST be 1 3 Open the machinery compartment access door 2 PILOT ORIFICE REPLACEMENT 2 1 Unscrew the brass fittings at both ends of the aluminum pilot tubing that connects the pilot orifice to the combination gas control valve This allows the tubing to be removed See Figure 1 Figure 1 Conversion component locations Solenoid valve PS360WB70 only Low flame bypass PS360WB70 only Combination gas control valve orifice Aluminum pilot tubing p n 36862 Jan 98 Rev Page 1 of 4 135 SECTION 3 SERVICING COMPONENTS 5 2 Appendix Instructions for Service 36863 Gas Conversion Kit for PS360EWB WB70 with Midco Burner Propane to Natural Gas 1 98 Remove and retain the aluminum pilot tubing from the burner assembly The end of the tubing that enters the combination gas control valve should be removed first Remove and retain the pilot orifice by unscrewing it counterclockwise from the burner plenum wall Unscrew and retain the pilot tubing connector and the pilot tap plug from the ends of the pilot orifice as shown in Figure 2 When these attachments have been removed discard the pilot orifice Screw the pilot tubing connector and the pilot tap plug into place in the new propane pilot orifice p n 31819 Tighten them to a snug fit Screw the new propane pilot orifice into its opening in the plenum wall Tighten it to a snug fit Ensure that the end of the orifice holding th
128. Noise Filter Capacitor Assembly on Temperature Controllers 9 93 YZ Bulletin MM 136 777 astmaster Middleby Cooking Systems Group Bus Boy Date 9 28 93 CTX 1400 Toastmaster Drive Elgin Illinois 60120 TAN 708 741 3300 Service amp Parts 708 741 4406 V Middleby 77748 Marshall Service Bulletin SUBJECT Digital Temperature Controller PN28071 0027 Blue or 28071 0028 Gray GENERAL some oven installations electrical noise static have caused the Digital Temperature Controller not to function properly Some common symptoms 1 The Controller Display changes and or may flash frequently 2 Temperature Set Point s may change without operator intervention 3 Gas solenoid opens and closes erratically The electrical noise static enters the Digital Temperature Controller circuitry through the thermocouple wires The thermocouple wires are attached to terminals 7 and 8 on the rear of the controller To correct this problem the supplied Filter Capacitor Assembly PN 27170 0283 should be connected from terminals 7 and 8 to Ground G APPLICATION Model PS200 Series Model PS250 Model PS300 Series and Model PS500 Series COMPATIBILITY The Filter Capacitor Assembly is installed on the rear terminal strip of either Digital Temperature Controller PN28071 0027 Blue or 28071 0028 Gray FEATURES Filters electrical notse static AVAILABILITY Effective Septem
129. Number Reference Thermocouples Part numbers are provided ONLY for the current 3 lead ther mocouple kits These thermocouples include instructions for replacing all previous thermocouple designs in all oven models P N Description 33984 Kit thermocouple PS360 series or PS555 570 series 33985 Kit thermocouple PS200 series or PS536 2 High limit thermocouple Middleby uses the term high limit thermocouple in reference to the thermocouple that sends its signal solely to the separate high limit control module If the oven does not have a separate high limit control module there is no high limit thermocouple On these ovens the temperature sensing thermocouple s con trol high limit activation Troubleshooting 1 Open thermocouple An open in a thermocouple will cause the temperature controller to read the maximum temperature usually 909 F 487 C This causes the following Onovens without a separate high limit control mod ule an open thermocouple triggers the high limit alarm This shuts down the burner After open has been corrected the high limit will need to be reset to allow the oven to resume operation ovens with a separate high limit control mod ule an open temperature sensing thermocouple causes the temperature controller to stop calling for heat This shuts down the burner ovens with a separate high limit control mod ule an open high limit thermocouple will trigger the high
130. O ONISIM TVOIH LO3 13 NOLLO3S 91 SIGNAL PRIMARY 240 50 60 Hz AMPLIFIER TEMPERATURE SECONDARY 24v 25 CONTROLLER PANEL GROUND 4 20 QUTPUT 151 SHROUD CONVEYOR CONTROLLER REAR FRONT AIR SWITCH 1 AIR SWITCH 2 PILOT IGNITOR poor GROUND 4 POLE MAGNET 2 PRIMARY 240V 50 60 Hz SECONDARY 247 65 conveyor tw contRower IGNITION MODULE POLE MAGNET SPLIT BELT ONLY PRIMARY 240 280 50 60 Hz SECONDARY 1 120 200VA HIGH LIMIT 51 4 3 SWITCH PS200 series gas oven with modulating valve 208 240V main blower motor and control circuit 208 240V 50 60 Hz 1 Ph 2 pole 3 wire supply 2 hot 1 ground SINVHOVIO ONISIM 0819 NOLLO3S YSL NOTE All wires are to be No 18 AWG T use In split belt applications only American Wire Gauge bik line 1 14 red 2 14 e 50 60 HZ M 4M AC AC SP Com Count 5V Terminal An 16 1 ___ 16_wht J2 16 Ko pins 1 12 ear Interloc 2 EX Switch C M ul d in v D C Motor D C Control J1 24 lt ei Door Interlock 4 0 6 Count 1 Switch bik 16 JC SP Com Count 46V Q3 Ke Thumbwheel Joa with 12 Hi
131. OLLO3S 891 TC GRO TO 183 GRD TC TO T8 GRO 3 we YO Th 7 TC RED TC AED TO 8 TC wea TO 5 2 cor 16 RED TES To Tas gt GAS Tg Rep wu Yo 5 TO Te wea TO 5 TEMPERATURE CONTROLLER SPLIT BELT ONLY CONVEYOR CONTROLLER PRmaRY 120V 0 60 Hz ty SECONDARY 227 ni rare 3 165 3C GRD GRO 55705 gas oven with modulating valve 208 240V main blower motor 120V control circuit 208 240V 50 60 Hz 1 Ph 3 pole 4 wire supply 2 hot 1 neutral 1 ground SINVHOVIO ONISIM 0819 NOLLO3S 691 COOL RG FAN LH MM E RED BLK frm wie E BLOWEA LEFT SIDE 25 cm 18 m I 23 eee sj MEAT SWITCH BLOWER SWITCH HEN n 8 pz BLOWER PRIMARY 2607 50 60 Hz RIGHT SIDE SECONDARY 24 25 TEMPERATURE AR SWITCH 3 FRONT RIGHT MODULATING 4 20 0 OUTPUT AR SWITCH 2 AIR SWITCH 1 REAR LEFT REAR RIGHT e A con 1 2 LS 4 bid FR LH NO 2 50 o o 8 LOAD XFHR2 BURNER PRIMARY 2609 BLOWER 50 60
132. OMER CONTACT THE GAS UTILITY SUPPLIER ENGLISH IX PILOT PRESSURE ADJUSTMENT 1 Unscrew the cap plug from the pilot pressure tap pilot tee and attach amanometer to the tap See Figure 6 Remove the pilot adjustment cap screw from the combination gas control valve Turn the oven on and allow it to heat to temperature Make a note of the customer s set point temperature After the oven has heated adjust the set point of the oven far lower than its current operating temperature This ensures that the pilot flame will be at its lowest level for some time Continued Figure 6 Measure inlet pressure here Measure pilot pressure here under cap plug 129 Adjust manifold pressure here under cap screw Measure manifold pressure here Adjust pilot pressure here under cap screw SECTION 3 SERVICING COMPONENTS e6ed HSITDNA gt Z e is Appendix Instructions for All Gas Conversion Kits for Ovens with Wayne Burner Propane to Natural Gas 8 00 5 The pilot pressure should be adjusted as follows X The current flow between the pilot hood and the 1 flame sensor when measured with a microamp meter or multimeter holds constant at a minimum of 2 0 uA See Figure 7 The pilot pressure as shown onthe manometeris in the range of 3 1 2 4 W C 8 7 10 0 mbar Adjust the pilot pressure as necessary by turning
133. ORTANT When replacing a controller you should ALWAYS replace the sleeve as well Some control ler models have sleeves of a similar size but with DIFFER ENT CONNECTIONS Using an incorrect sleeve can dam age the controller and cause the oven to function incor rectly Exception The sleeve used on Controllers 36056 and 46837 is identical except for the information label C High Limit Cooldown Functions Except where noted in Section A Part Number Reference the temperaturecontroller incorporates circuitry for the high limit and cooldown functions 1 TheHigh Limit function terminals 11 and 12 will shut off the burner heating elements if the oven temperature sensed by the thermocouple s exceeds 650 F 343 C This function is used on most PS200 series and PS360 series gas ovens All other oven models use a sepa rate high limit control module If the high limit temperature is reached an indicator on the controller will illuminate The current controller P N 46837 has a lamp marked to show this condition Older controllers will have different indi cators you should refer to the operating instructions for the controller in question for assistance 2 The Cooldown function allows the blowers to continue in operation after the operator switches off all operating switches on the control panel The blowers will remain in operation until the cooldown switch opens usually 180 F 82 C Appendices D
134. Pickup assembly PS350 style or old style Current style pickup assembly see Figures 16 17 P N Description 27170 0263 Pickup assembly current Preparing to Service the Speed Controller NOTE To properly service this equipment you must use a digital meter An analog meter will not work 1 Before troubleshooting the conveyor speed controller check the following a Conveyor belt is tight b Drive chain is tight and aligned Set screws on drive sprockets are tight d Axial fan s are running and clean of dust and de bris e Motor and pickup wires are secure at the Conveyor Terminal Block location of the block varies by oven model f Wire connections on conveyor speed control mod ule including the ribbon cable to the thumbwheel display unit are secure Check the pickup for the following See Figures 14 17 Pickup is secure Magnet is not cracked or chipped Magnet is not rubbing on plastic housing Mounting bolt is not worn or bent Pickup bearing in good condition On PS350 style pickup Fig 14 gap between magnet and Hall Device is spaced approximately 1 64 1 32 0 4 0 8mm or a business card thick ness 14 Figure 14 PS350 style pickup assembly used on early PS360 4 Pole Magnet Internal Tooth Lockwasher Figure 15 Old style pickup assembly Access Cover 10 32 x 1 Hex Hd Screw 4 Pole Magnet Lockwasher Hall Device Figure 16 Curre
135. ROUND POSITIVE PROBE E CURRENT AC VOLTAGE 1 PILOT FLAME PILOT HOOD NEGATIVE PROBE TO GROUND AND SENSING CIRCUIT FLAME SENSOR FLAME SENSOR AC VOLTAGE THE FOLLOWING CONDITIONS WILL HAVE A DIRECT BEARING ON EVERY IIDAPPLICATION Voltage The supply voltage to the ignition controls should be within the following ranges e 120VAC controls 102 to 132VAC e 24VAC controls 21 to 26 5VAC 24VAC systems should use transformers that will pro vide adequate power under maximum load conditions Gas Pressure Inlet gas pressures Natural gas Wayne burner 6 12 W C 14 9 29 9 mbar Propane Wayne burner 1172 12 W C 28 7 29 9 mbar Midco burner all gases 6 14 W C 14 9 34 9 mbar Regulated gas pressures Natural gas Wayne burner 3 5 W C 8 7 mbar Propane Wayne burner 10 W C 24 9 mbar Midco burner all gases 3 5 W C 7 5 12 5 mbar Pilot gas pressures Natural gas Wayne burner 372 4 W C 8 71 9 95 mbar Propane Wayne burner 8 10 W C 19 9 24 9 mbar Midco burner all gases 5 6 W C 12 5 14 9 mbar Temperature Ignition controls should not be exposed to tempera tures exceeding 140 F 60 C or less than 40 F 40 C Pilot Application The pilot and flame sensor application is the most criti cal aspect of the IID application The pilot flame must make contact with the pilot tip and surround the flame sensor probe A multimeter or ampmeter set to
136. SINVHOVIO ONISIM 0819 NOLLO3S NOTE All wires are to be No 18 AWG American Wire Gauge 4 EM S 208 240 x v Ela 50 60 HZ n 2 e Terminal 14242945 Go n 116 neutrali 16 wht C6 Rear Interlock LUNES ilo o1 Switch akj yjz z Hai Door Interlock 01 Switch blk 16 Q gt 2 19 wht 1 37 Pressure Switch Switch i roy 650 F 349 C D om Temperature Controller 78 69 59 4712 2 3 2 gi ED wht c co T C G6 High Flame Solenoid Valve eS ee use In split belt applications only ees 7 D C Motor D C Pick up SP Com Count 5V D C Motor D C Control AC SP Com Count 5V Conveyor Switch wht E a ab Coll Fan Motor Cooldown TC 1 2 wht 180 F bin 82 Valve Terminals MV n 5 Ignitor Pilot Sensor Burner Gnd Switch To Gas Control Pilot Outlet wht 5200 gas oven with solenoid valve and digital temp control 208 240V main blower motor 120V control circuit 208 240V 50 60 Hz 1 Ph 3 pole 4 wire supply 2 hot 1 neutral 1 ground SINVHOVI
137. TION 3 POSITION T NON BRIDGING t BRIDGING COIL CONTACTS CONTACTS 2 3 CONTACTS TO SUIT NEEDS PUSHBUTTONS SINGLE DOUBLE CIRCUIT MAINTAINED CONDUCTORS CIRCUIT T 176 THERMOCOUPLE SWITCH E SECTION 5 REFERENCE Common electrical wiring diagram symbols continued CONNECTIONS CONT D CONTACTS DEL AY COIL EAM ETC THERMAL rassis NOT NORMALLY __0E ENERGIZED CLOSED LOAD DM OPEN CLOSED OPEN S CLOSED COILS RELAYS SOLENOIDS BRAKES THERMAL M ME CIRCUIT TIMERS 2 POSITION 3 POSITION 2 POSITION Eg M ME ETC HYDRAULIC PNEUMATIC LUBRICATION Eg Ope ee ES COILS CONTINUED LINEAR VARIABLE VARIABLE AUTOTRANSFORMER TRANSFORMER DIFFERENTIAL TRANSFORMER AUTO TRANSFORMER EE MOTORS 3PHASE DC MOTOR DC MOTOR MOTOR ARMATURE FIELD Iu RESISTORS CAPACITORS ETC HEATING TAPPED eem 177 SECTION 5 REFERENCE Common electrical wiring diagram symbols continued RESISTORS CAPACITORS ETC CONTINUED CAPACITORS METERS METER FUSES SHUNT ALL TYPES 6 Decem RESISTORS CAPACITORS ETC CONTINUED LIGHTS HORN SIREN THERMOC PLE BATTERY PuSH TO TEST TO TEST pe gt LETTER DENOTES COLOR DENOTES COLOR ELECTRONIC TUBES COLD 9 DOT
138. TIONS Continued 0197 Insert the other 8 32 x 3 4 19mm screw into the upper left mounting hole near the blue knob Tighten both screws to fasten the Air Pressure Switch securely to the Mounting Bracket To allow screw driver access to the screw head turn the blue labeled knob until its notch aligns with the mounting hole Unscrew the Coupling Nut on the Air Pressure Switch Remove the rubber washer and the metal washer inside the Threaded Coupling Insert each of the two wires through the Coupling Nut the rubber washer the metal washer and finally through the Threaded Coupling of the Air Pressure Switch Pull enough wire into the Air Pressure Switch for the electrical connections as shown in Figure 3 Connect the orange wire labeled Common to the switch terminal marked COM Common and P Figure 3 by loosening the terminal screw and wrapping the wire around the threaded portion of the screw Tighten the screw for a good electrical connection Connect the wire labeled Normally Open to the switch terminal marked NO Normally Open and 2 OR if the wire is labeled Normally Closed connect that orange wire to the switch terminal marked NC Normally Closed and 1 wrapping the wire around the threaded portion of the screw Tighten the screw for a good electrical connection Bend the wires only enough to avoid sharp kinks or other interference as they exit the Air Pressure Switch Slide
139. To correct this situation 40A fuses were used 2 91 and later NOTE All control wire used on this oven is AWM rated at 221 F 105 C DO NOT replace with lower rated wire Figure 80 Removing the element bank mounting bolts 142 Part number reference Part No Description 27374 0001 Heating element 208V 27374 0002 Heating element 240V 27374 0003 Heating element 380V 28041 0016 Mercury contactor 3 pole 30A 27170 0251 Contactor tube replacement kit 27170 0250 Coil replacement kit 28154 0002 Fuse 30A class M early 28150 0134 Fuse 40A class T current 27021 0016 Fuse block 40A used when upgrading from 30A to 40A fuse qty 3 reqd Supply Ovens have a 208V 220 240V 380V 416V or 480VAC electrical supply The control current of the oven oper ates at 110V single phase If the oven was specified for a 3 wire system it was supplied with an optional control transformer to step the 3 phase current down for the control circuit If the oven was specified for a 4 wire system the 4th neutral wire is utilized to split 2 of the 3 incoming 3 phase legs and obtain a separate 110V circuit Figure 81 Electrical leads disconnected Heater specifications e PS amp 310 360 series electric ovens use 18 heating elements in 3 banks 6 elements per bank e 208V elements are used for ovens with 208V supply 240 volt elements are used for ovens with a 220 230 or 240V supply
140. Troubleshooting 1 Troubleshooting the Temperature Controller and Thermocouple s using the Altek Thermocouple Source Middleby P N 27170 0192 e Turm the heat switch OFF e Disconnectthe thermocouple leads from Terminals 7 and 8 on the temperature controller Tape the ends to prevent shorting Connectthe white lead ofthe Thermocouple Source to Terminal 8 Connect the red lead of the Ther mocouple Source to Terminal 7 Set the Thermocouple Source as close as pos sible to the customer s set point Then turn the BLOWER switch to the ON position The temperature controller should read close to the customer s set point Failure indicates a problem with the temperature controller If the temperature control ler is functioning properly check the thermocouples Refer to Section IV Thermocouples 2 Troubleshooting the High Limit Switch On ovens that use the high limit function of the tem perature controller most PS200 series and PS360 se ries ovens an intermittent high limit switch will cause intermittent operation of the burner If you suspect that this is a problem a good check is to place a 1A fuse in parallel around the switch contacts terminals 11 and 12 If the switch is functioning properly the fuse will never carry a load The only time the switch would open would be under a no load condition If the switch is trying to open intermittently however the full current load of the blowers will be c
141. Vs transformer 27170 0017 Relay 27170 0016 Combination gas control valve 1 2 45688 OVENS WITH T ON OFF GAS 1 2 union SYSTEM ONLY 23051 0003 Pilot Solenoid valve 1 2 Pilot line pressure Manual shutoff Bypass line 1 4 aluminum tap valve 1 2 1 4 aluminum tubing 30185 23115 0009 tubing 15125 0002 15125 0002 per foot per foot Figure 55 5310 PS314 PS360 or PS360WB gas train Burner blower and motor assy 120V with centrifugal safety switch 27170 0011 Air shutter 42810 0087 Solenoid valve 1 2 28091 0017 Junction box Includes 240Vp 120Vs transformer 27170 0017 Relay 27170 0016 Combination gas control valve 1 2 45688 1 2 union 23051 0003 Pilot line Manual shutoff 1 4 aluminum valve 1 2 tubing 23115 0009 15125 0002 5 per foot ypass line tap 1 4 aluminum tubing 30185 15125 0002 per foot 88 SECTION 3 SERVICING COMPONENTS Figure 56 PS360EWB or PS360WB70 gas train with Midco burner PS360WB70 PS360WB70 ONLY Air tube ONLY Solenoid valve 3 4 silicone rubber Bypass line 31500 22450 0297 Air shutter 1 4 aluminum per foot 36830 tubing TO NEGATIVE 15125 0002 SIDE OF AIR per foot SWITCH PS360EWB ONLY M420 modulating valve 3 4 Burner blower motor AA UNE 208 240V 23051 0004 32195 Manual shutoff valve 3 4 23115 0010 Pilot pr
142. X 847 741 4406 Middleby Corporation Service Hotline 1 800 238 8444 12 SECTION 3 SERVICING COMPONENTS V BLOWERS Figure 25 PS200 series ovens Early style PS200 indirect drive assembly All PS200 ovens are equipped with one 1 3hp blower mo Ud a tor The motor indirectly drives a pulley on the shaft of the blower fan with a fan belt Two main designs exist for the PS200 indirect fan drive assembly Early design used through 6 90 This design used 1 2 12 7mm bore flange mount bearings and a 1 2 12 7mm diameter blower fan shaft See Figure 25 e Current design used 7 90 and later This design uses 5 8 15 9mm pillow block bearings and a 5 8 15 9mm diameter blower fan shaft See Figure 26 Blower motors on both versions are rated for 208 240V Ta single phase and are protected Direction of rotation viewed from A built in thermal overload protection device rear of oven Two 9A fuses on the inside of the machinery compart ment door Fuse location is shown in Figure 27 In addition the blower fan is protected by an air pressure Figure 26 saftety switch that prevents the burner heating elements Current PS200 indirect drive assembly from activating if the fan is not rotating See Air Pressure Safety Switch on Page 81 1 Partnumber reference Early version components NOTE If an early version PS200 series oven has failed fan shaft upgrade the oven to the current dr
143. XFMR2 VALVE TEMPERATURE SWITCH g 5 CIT ine 7 zov CONTROLLER 50 60 Hz SECONDARY 24V 5 65VA FRONT 5 co we je FLOOR 5 5 GROUND io i 8 H 67 ___ Q 8 FN 64 5 5 SIGNAL 2 AMPLIFIER PS555G or PS570G gas oven 208 240V main blower motor and control circuit 208 240V 50 60 Hz 1 Ph 2 pole 3 wire supply 2 hot 1 ground SINVHOVIGO ONISIM 0819 NOLLO3S COTE GAUCHE COTE LEFT SIDE RIGHT SIDE E edil COMMUTATEUR Pt e VENTILATEUR 1 E PRINCIPALE food i Ba i D i Borner HE INTERRUPTEUR sean POTS UMITEUR COMMUTATEUR CONVOYEUR MOTOR CONVOYEUR CONTROLEUR DE TEHP RATURE AMANT amp POLES Cervo noton MOTEUR CONVOYEUR RPM CAPTEUR EHAUFF AGES CHAUFFAGES CHAUFFAGES CHAUFFAGES HEATER VOLTAGE HEATER VOLTAGE HEATER VOLTAGE HEATER VOLTAGE SPECIFIC RATED RATED SPECIFIC RATED SPECIFIC RATED 208 OR 230 VOLTS 208 OR 230 VOLTS 208 OR 230 VOLTS 208 OR 230 VOLTS B KW C B kw a Kw LEFT SIDE RIGHT SIDE COTE GAUCHE COTE DROIT 5555 electric oven 208 240V main blower motor heating elements and control circuit 208 240V 50 60 Hz 3 Ph 3 pole 4 wire supply 3 hot 1 ground SINVHOVIO ONISIM 0819 NOLLO3S SECTION 5 REFERENCE ee
144. a Oot pounds ba inches T ps watt horsepower hrs meters kilowatts BTU min wa kilowatt hours yards kilowatts horsepower eet of water atmospheres kilowatts Watts eet of water in ofmercury kilowatt hours BTU eet of water kg sq cm liters gallons eet of water lbs sq ft liters _ pints liquid eet of water lbs sq in psi liters quarts Pressure conversions in in Hg mbar psi oz Isq in in in Hg mbar psi oz Isq in 0 10 0 007 0 20 0 0036 0 0577 8 00 0 588 20 0 0 289 4 62 0 20 0 015 0 50 0 0072 0 115 9 00 0 662 224 0 325 5 20 0 30 0 022 0 75 0 0108 0 173 10 00 0 74 25 0 0 361 5 77 0 40 0 029 0 98 0 0145 0 231 11 00 0 81 274 0 397 6 34 0 50 0 037 1 25 0 0181 0 289 12 00 0 88 29 8 0 433 6 92 0 60 0 044 1 50 0 0217 0 346 13 00 0 96 32 5 0 469 7 50 0 70 0 051 1 72 0 0253 0 404 13 60 1 00 33 8 0 491 7 80 0 80 0 059 1 98 0 0289 0 462 13 90 1 02 34 5 0 500 6 00 0 90 0 066 2 23 0 325 0 520 14 00 1 06 35 8 0 505 8 08 1 00 0 074 2 50 0 036 0 577 15 00 1 10 37 2 0 542 8 7 1 36 0 100 3 38 0 049 0 785 16 00 1 18 40 0 0 578 9 2 1 74 0 128 4 33 0 067 1 00 17 00 1 25 42 3 0 614 9 8 2 00 0 147 4 97 0 072 1 15 18 00 1 33 45 0 0 650 10 4 2 77 0 203 6 87 0 100 1 60 19 00 1 40 47 4 0 686 10 9 3 00 0 221 7 48 0 109 1 73 20 00 1 47 49 7 0 722 11 5 4 00 0 294 9 95 0 144 2 31 25 00 1 84 62 3 0 903 14 4 5 00 0 368 12 4 0 181 2 89 27 20 2 00 67 7 0 975 15 7 6 00 0 442 14 9 0 217 3 46
145. ack wire from the prepurge relay coil When reconnecting the module wires be sure the yellow wire which is actually the ground wire is connected to the top terminal marked 24v on the old module Reconnect the ignitor sense lead to spark terminal of old module The adapter in Figure 4 of the new module is not used NOTE The new style ignitor sense lead as shown in Figure 5 will not be compatible with the old module Either a new module must be used or the ignitor sense lead must also be replaced with an old style 116 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 42810 0114 Ignition Module 11 90 Wire Nut Containing Common Wires of XFMR Relay Cail and ignitor Module f Burner Blower Motor And Centrifugal Switch Figure 1 Wire Nut Containing Common Wires of XFMR Relay Coil and ignitor Module Commen Ground Wire in Place Burner Blower Motor And Centrifugal Switch Figure 2 117 To Ground Terminal 3 On Main Gas Valve New Igniter Module 27161 0005 Internally Grounded To Ignitor ___ gt Sensor Old ignitor Module P N 27161 0004 internal Ground To Ground Terminal On Main Gas Valve Igniter 3 Sensor SECTION 3 SERVICING COMPONENTS Appendix Position of Combination Gas Valve Components during Burner Operation 4 02 SECOND AUTOMATIC VALVE OPERATOR SECOND AUTOMATIC OPERATOR SOLENOID SERVO
146. activate the heating elements at 100 power on a fixed cycle time for a length of time propor tional to the signal from the temperature controller A HEAT indicator on the Temperature Con troller will light to show whether the Controller is calling for heat F High Limit NOTE Electric oven models use a separate High Limit Control Module The High Limit relay will shut the oven burner OFF 1 Ifthe high limit thermocouple senses an oven tem perature above 650 F 2 If the signal from the high limit thermocouple is lost An indicator on the Temperature Controller will show a high limit condition This indicator varies by Tempera ture Controller model Refer to the instructions for the appropriate Temperature Controller for an illustration and description of this indicator Cooldown When the heat and blower switches are turned OFF the cooldown relay will allow the blowers to remain ON until the oven temperature falls to 200 F 93 C During cooldown the Temperature Controller will con tinue to show the oven temperature SECTION 2 AIR FLOW AND HEAT TRANSFER SECTION 2 AIR FLOW AND HEAT TRANSFER TYPES OF HEAT TRANSFER Heat constantly moves from a warm object to a cold ob ject Heat moves in three different ways thorough con duction through radiation and through convection Middleby Marshall conveyor ovens use all three of these paths to cook the product Conduction Heat is transfe
147. ain the set point As of 1 02 only the PS536 Electric oven uses the variable pulse system Other oven models equipped with this system will be announced by Middleby as they become available For all other ovens gas or electric that use the on off system the jumper may be set to either position After the jumper has been properly set replace the controller into its sleeve and tighten the screw Figure 6 Programming 1 Restore electrical power to the oven 2 Refer to Figure 7 Set the following options according to the customer s preferences e SetPoint locked or unlocked Degrees Fahrenheit or Celsius e SetPoint or Actual Temperature display Set the controller to PID or On Off operating mode Choose the PID mode for BOTH gas ovens with the modulating system AND for elec tric ovens with the variable pulse system Adjust the Set Point according to the customer s specifications If the PID operating mode was chosen per form an Auto Tune calibration as per the in wi structions in Figure 7 lt gt We BR Check that the customer is familiar with the p operation of the controller The last page of Jumper settle the WI dumper is Sette the W2 these instructions includes an operating guide position for gas ovens with position for electric ovens for the controller Remove this page and leave modulating gas system with variable pulse system it with the customer for future reference Page 6 of 10 SERV
148. al Ser vice Department Figure 2 Air finger operation Hot air flow from blower wheel s Vertical columns of high velocity hot air AIR FINGERS A Description and Function Air fingers direct the heated air from the blowers into vertical jets that are directed at the top and bottom of the conveyor belt Each air finger configuration has been tested to optimally cook a specific customer s product As a rule air finger configurations should NOT be changed from customer specifications without di rect instructions from the Middleby Technical Services Department Middleby uses two main types of air fingers PS300 350 and early PS310 360 ovens used a shut ter type air finger assembly The finger is as sembled from a manifold inner plate and outer plate The inner plate is assembled from two sepa rate plates each with a series of holes that are riveted together The plates can be repositioned relative to each otherto restrict the air flow through the holes as necessary These fingers are no longer in general use but may still be found in older ov ens in the field See Figure 3 All current ovens use an air finger which is com posed of a manifold inner plate and outer plate No adjustments are necessary or possible to these fingers but a wide variety of styles is available to meet different customers baking needs See Fig ure 4 Figure 3 PS300 350 air finger with shutter plate Outer plate
149. al Temperature Controller Kit 2 02 Jumper Setting Loosen the Phillips screw at the bottom center of the faceplate Then pull the controller out of its sleeve Next access the jumper shown in Figure 6 This jumper affects the signal that is output from Terminals 15 and 16 The jumper MUST be the correct position for proper operation of the controller CAUTION If the jumper is incorrectly set the oven will be unable to properly maintain temperature In addi tion DAMAGE MAY OCCUR TO THE CONTROLLER AND OTHER OVEN COMPONENTS Always make sure that the jumper is correctly set BEFORE restoring power to the oven For gas ovens equipped with the modulating gas system the jumper must be set to the W1 position This instructs the controller to send a variable current 4 20 mA signal from Terminals 15 and 16 to the amplifier board The board converts this to a 0 24VDC signal which is sent to the modulating valve The valve regulates the gas flow according to the need for heat to maintain the set point For gas ovens you should always check inside the machinery compartment to see whether a modu lating valve is present in the unit before setting this jumper For electric ovens equipped with the variable pulse system the jumper must be set to the W2 position This instructs the controller to send a constant current pulsed 20VDC signal to the relay Once per second the signal pulses on proportional to the need for heat to maint
150. all the way in slide compression fitiing into place and engage threads tum until finger tight Then tighten one more turn with wrench Do not overtighten 5 Slide the compression fitting suppiled with the over the other end of the tube Push tubing Into the pilot fitting located on the bumer plate until It bottoms White holding tubing all the way in slide compression fitting into place andengage threads Turn until tingar tight Then lighten one more turn with wrench Do not overtighten Do Not apply jumpar across or short the valve coll terminals Doing may burn out the heat anticipator in tha thermostat or damage th elecuonic modula WIRING Disconnect power supply be lore making wiring connactlon to prevent electrical shock or equipment damaga Connect wiring from the ignition module to the gas valve Refar to Figure 2 i COMBINATION IONITION MODULE Figure 2 Wirlng 113 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 42810 0121 Combination Gas Valve 1 92 FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEVERE INJURY OR DEATH Check for gas leaks with rich aoap and water solution any time work is done on a gas control GAS LEAK TEST 1 Paint all pipe connections upstream of the gas control with a rich soap and water solution Bubbles Indicate gas leak 2 it a gas leak is detected tighten the pipe connection 3 Stand clear while lighting maln bumer to preven
151. and pick ups Consult the gear motor sprocket combinations chart contained in the attached instructions for optional conveyor speed set ups The replacement thumb wheels used on both DIP switch controls can be interchanged Availability orders for replacement controls will be filled with control PN 31020 newly manufactured ovens are fitted with contro PN 31020 Continue to order replacement controls under kit PN 42810 0133 which wiil contain the attached updated instructions along with contro 31020 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 42810 0133 Conveyor Speed Controller Kit with Thumbwheel 4 95 DIP Switch Conveyor Control Installation and Diagnostic Instructions Part Number 88210 0077 General The following provides instructions for the Installation and Diagnostics of the DIP Switch Conveyor Con trol Part Number 28074 0018 or Part Number 31020 contained in kit Part Number 42810 0133 Either of these controls can be installed into the PS200 300 and the 500 Series Ovens Note If installing PN 28074 0018 control into a PS570 S chain driven conveyor oven be sure the control is marked Revision B on the label A DIP Switch Control Installation The DIP Switch Conveyor Control Module is installed and secured with Phillips Head Screws and Exter nal Tooth Lockwashers not supplied in the oven control compartment The Thumb Wheel is installed in arectangular
152. arge the low flame will be too high In some cases this will prevent the oven from being able to maintain the set point Refer to the chart on Page 91 to determine the proper size forthe bypass orifice Figure 70 Low Flame Bypass Orifice Bypass line configuration varies depending on the oven model Refer to the drawings on pages 88 90 Low flame bypass orifice Bypass line 96 Solenoid valve Modulating Gas Valve if so equipped Ovens that use a PID modulated gas regulation system are equipped with a modulating gas valve instead of a sole noid valve The valve is located between the combination gas control valve and the burner In response to the millivolt signal from the thermocouple the Digital Temperature Controller sends a 4 20mA signal to an amplifer board The board in turn passes on 0 20VDC signal to the modulating valve itself The valve opens or closes proportionally to the signal from the amplifier board allowing any setting from 0 100 gas flow When the oven is switched on gas demand is at its peak and the valve is fully open permitting 100 gas flow As the oven s temperature approaches the set point the valve slowly begins to close restricting gas flow to the 35 60 range After the oven is fully preheated the gas flow usu ally stabilizes at about 30 The actual oven temperature can remain constant with NO temperature swing because the valve is adjusted constantly accordin
153. arried by the fuse Regardless of the oven model this load is far greater than 1A and the fuse will blow Appendix Temperature controller terminal cross reference 4 02 Terminal for Terminal for 28071 0012 and Terminal for 36056 and Description 28071 0018 34983 46837 TC 8 TC 7 COM 5 NO 4 L2 L2 TC TC Input to Temperature Control Relay Output to High Flame Solenoid or Heater Contactors Neutral Power Ground Input to Cooldown Relay Output from Cooldown Relay Input to High Limit Relay Output from High Limit Relay PID or Variable Pulse Output PID or Variable Pulse Output SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 47321 Digital Temperature Controller Kit 2 02 Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 USA 847 741 3300 FAX 847 741 4406 o Middleby 2728 Marshall Instructions for Service Kit 47321 Digital Temperature Controller Installation Programming and Troubleshooting Instructions 2 Middleby 77248 Marshall d 1 5 ACTUAL TEMP l 117 HEAT EEE sP LOCK OVER TEMP L1 ij KIT COMPONENTS Qty P N Description 1 46837 Digital Temperature Controller On Off Gas amp Electric PID Gas and Variable Pulse Electric operating modes with mounting brackets
154. as Control Conversion Tag P N 22501 0007 See Figure 8 Fasten the tag onto the gas piping next to the combination gas control valve Locate the round NAT label green or yellow on the burner or burner motor Attach the kit supplied red LPG label P N 22500 0065 on top of the NAT label The newlabel should completely cover the NAT label See Figure 8 Complete the information on the Gas Conversion Label as shown in Figure 8 Attach the Gas Conversion Label in plain view on the outside of the oven as close as possilble to the oven s serial plate Attach on top of existing NAT label on burner o burner motor New label completely covers NAT label Date of conversion NO BY __ CORRECTNESS OF THIS CONVERS Part no of this Kit see chart on Page 1 THIS APPLIANCE HAS BEEN ON WHO ACCEPTS THE RESPONSIBILITY FOR TO PROPANE GAS WITH KIT Measured value ION MAIN BURNER ORIFICE SIZE from Section X MANIFOLD PRESSURE 14 W C 34 9mbar MODEL NO INPUT RATI Stated on the oven s serial plate MAXIMUM INLET d 124 Attach completed label in plain See chart on view near serial plate Page 1 Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 USA 847 741 3300 FAX 847 741 4406 SECTION 3 SERVICING COMPONENTS Appendix Instructions for All Gas
155. ate a prob lem with the lower air fingers Ifthe oven has the current standard air finger type you should contact Middleby Technical Services for assistance Ifthe oven has the PS300 350 style air fingers with a shutter plate it is possible to adjust the posi tions of the air shutters to correct a front to back bake problem Proceed to Step D PS300 350 Air 10 Figure 7 Front to back uneven bake NOTE Inthis example the front of the product is darker than the rear The opposite condition is also possible Finger Shutter Adjustment D PS300 350 Air Finger Shutter Adjustment Before attempting to properly balance a Middleby Marshall oven equipped with shutter fingers you should understand the principles of operation of this type of finger The oven moves approximately 2000 of air per minute When this large amount of air is moved through the plenum and fingers it rushes through the plenum and to the end of the air finger This creates a back pressure of air inside the finger and tends to deliver more air onto the product at the front of the air finger The inner plate has a separate shutter plate riveted to it at a slight angle Since there is more pressure at the end of the fingers front of the oven than at the plenum rear of the oven the shutter plate is angled to restrict the air flow near the front of the oven This creates a proper balance permitting an even amount of air t
156. ation OFF for 2 minutes 2 Turn the Blower Switch or HEAT Switch as per Step 1 ON 3 Ifthe problem does not clear contact the Middleby Technical Ser vice Department for assistance Check that the thermocouple leads are properly connected to Ter minals 7 amp 8 ofthe temperature controller Checkthe continuity of the thermocouple at room temperature You should measure 9 20 Ohms of resistance Ifthe reading was outside the correct range the thermocouple has an open Remove and replace the thermocouple If the reading was inside the correct range contact the Middleby Technical Service Department for assistance Checkthe polarity of the thermocouple leads The red wire should be attached to Terminal 7 on the temperature controller The white wire should be attached to Terminal 8 2 Ifthe polarity connections are incorrect connect the thermocouple properly If the polarity connections are correct replace the thermocouple Page 8 of 10 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 47321 Digital Temperature Controller Kit 2 02 Digital Temperature Controller P N 46837 Operating Instructions Display HEAT ON Light Shows the Set Point or Lights when the the Actual Tempera burner or heating ele ture in degrees Fahr ments as appropriate enheit F or Celsius for the oven model C are in operation SP LOCK Light Lights when the set point is locked
157. ature Controller Heat Switch Closing the heat switch completes a circuit 1 Through the heat switch 2 Through the blower motor centrifugal switches or air switches as appropriate for the oven model Through the high limit switch One circuit then goes to the a Burner L1 b Transformer 110V to 24V Motor relay coil On cold start the heater on this relay takes about 30 seconds to warm up before the relay will energize This gives an additional prepurge The relay is not used on ovens with 208 240V burner blower motors d Burner blower motor As the motor reaches full operating speed the centrifugal switch or air flow switch as appropriate for the oven model closes and applies voltage to the burner con trol This energizes the ignitor control spark transformer and the pilot valve The spark then lights the pilot The flame sensor proves the presence of the pilot flame and the ignitor con trol then shuts off the spark At the same time the main burner valve is opened The main burner is then ignited If the pilot does not light within approximately 90 seconds the oven will shut down The pilot and main gas valve will stay on open as long as the heat switch is ON and the flame is proven If the flame goes out for any reason the pilot will try to light for 90 seconds and then go into automatic lockout To relight the pilot after it has gone into automatic lockout the burner must be turned OFF for
158. back voltage circuit that allows the module to operate without a signal from the burner blower assembly This procedure is explained in greater detail in the instruc tions for Kit 42810 0114 included in the Appendices section 2 Module Operation The ignition module delivers 24V to the pilot ignitor when the blower motor centrifugal switch or air pressure safety Switch is closed When the module detects a current flow of at least 2 0 uA through the pilot flame it supplies 24V to the combination gas control valve allowing the valve to operate Figure 73 Wiring diagram of ignition and gas valve system obsolete ignition module 27161 0004 Wire Nut Containing Common Wires of XFMR Relay Coil and ignitor Module Ground Wire In Place Old ignitor Module P N 27161 0004 internal Ground To Ground Terminal On Main Gas Valve To L2 Burner Blower Motor ignitor 3 And Switch Sensor Figure 2 Figure 74 Wiring diagram of ignition and gas valve system current ignition module 27161 0005 Wire Nut Containing Common Wires of XFMR Relay and ignitor Module Common Ground Wire Removed and Discarded Burner Blower Motor And Centrifugal Switch Figure 1 To Ground Terminal On Main Gas Vaive New ignitor Module A P N 27161 0005 Internally Grounded To p Sensor SECTION 3 SERVICING COMPONENTS
159. ber 20 1993 part orders for the Digital Temperature Controller include the Filter Capacitor Assembly installed on rear of unit SECTION 3 SERVICING COMPONENTS Appendix Service Bulletin MM 136 Electrical Noise Filter Capacitor Assembly on Temperature Controllers 9 93 Effective September 20 1823 ovens shipped with tne Digital Temperature Controller include the Filter Capacitor assembly installed Effective October 1 1993 Middleby Marshall will fill all Orders for the Filter Capacitor Assembly DISPOSITION OF INVENTORY All distributor inventory should be upgraded with the filter capacitor assembly INSTALLATION PROCEDURES To Install the Filter Capacitor Assembly PN 27170 0283 proceed as follows 1 Turn OFF all power to the oven 2 Open the Control Compartment Install the filter capacitor assembly on the terminals Refer to Figure 1 The capacitors should be mounted across the back of the controller The joined leads of the two capacitor assembly are connected to Ground G Either single capacitor lead is connected Terminal 7 and the other singie capacitor lead is connected to Terminal 8 Close the Control Compartment Turn Oven ON check and or set the set point s monitor for stable display s and operation Refer to appropriate documentation covering the Digital Temperature Controlfer Filter Capacitor Assembly To be installed White T C Red T C a 5 999606606
160. bolts before installing back wall assem bly to oven 17 Install back wall on oven 18 Install fan belt NOTE Excessive fan belt tension will create overload ing of rear bracket fan shaft bearing Refer to Blower Belt Tension on Page 69 Figure 31 Fan shaft alignment tool SECTION 3 SERVICING COMPONENTS Figure 32 Bearing replacement and alignment early style PS200 fan shaft assembly 5 Assembly 6 Bracket 7 2 3 4 14 41 12 4 places Grease Fittings Pointed Upward 8 9 1 11 167 4 Welds 1 1 16 Fittings Pointed Upward 14 8 Item Qty Part Number Description Qty Part Number v Description 1 1 Not available Back Wall Assembly 9 1 21651 0008 Square Key 1 8 2 8 21216 0001 Screw Hex Cap SS 3 8 16x1 10 2 22071 0010 Flange Bearing 5 8 Bore 3 16 21422 0001 Lock Washer Split 3 8 11 6 21211 0004 Screw Hex Cap 1 4 20 x 3 4 4 20 21416 0001 Flat Washer SS 3 8 12 6 21421 0016 Lock Washer Split 1 4 5 1 Not available Indirect Fan Drive Bracket Assembly 13 1 Not available Blower Fan 16 Dia 6 1 Not available Bracket Indirect Drive 14 4 21419 0004 Flat Washer 3 8 SS Special 7 1 Not available Shaft Fan Drive 15 1 37900 0094 Fan Shaft Alignment Tool 8 1 22230 0072 Pulley 1 2 Bore IMPORTANT f parts listed as Not Available require replacement use Service Kit 49810 0121 to upgrade the fan shaft assembly to the
161. brn blu Hi Limit 3 5 mn ende 9 650 Ural Terminals mp XFMR 4 ge 24V a 115V Temperature 71 wht Controller 12 2p Gp 59 go 79146 1221 TC ilot 3 C Burner Wee D bik Soph ulL 4 Centrifugal Sensor Grd High Flame Switch To GasControl C nleno 5 wht Pilot Outlet Light Heat Sw PS310 314 360 360WB gas oven with analog temp control 208 240V main blower motor 120V control circuit 208 240V 50 60 Hz 1 Ph 3 pole 4 wire supply 2 hot 1 neutral 1 ground SN3AO 531435 09254 SINVHOVIO ONISIM TVOIH LO3 13 NOLLO3S LOL 2 3 NOTE All wires are to For use In split bell applications only 208 240V be 18 AWG unless 50 60 HZ yi sil olherwise specified D C Motor E E Hm xi EB M M SP Co Door Switch 0257 2 olg wht Conveyor Switch M2 Motor Blower H Swilch ooling Fan Switch 9 110 ES Cooldown TC Coll Blwr Mtr 180 F brn Vaive Hi Limit FC yel Terminals 650 F 343 C purple Relay Coll 0 24V e 3 5 9 RC 115V 24V Gnd Pilot Temperature 7 7 24V Burner Controller gin ignitor 1 la 7 oe 59 2 L2 119 e Ignition Sensor Pilot xs _____ Module J gud 5
162. bypass orifice Slip the kit supplied bypass orifice into the discharge end of the bypass tube as shown in Figure 3 With the orifice in place push the tube back into the compression fittings until it bottoms While holding the tube in place slide the compression nuts into place Tighten them to a snug fit with your fingers Gently tighten the nuts one complete turn with a wrench DONOT OVERTIGHTEN THE COMPRESSION NUTS 121 Figure 1 55705 gas train with solenoid valve shown Refer to the illustrations on Page 2 for component placement for other oven models ENGLISH Figure 2 Adjustment screw Ny Regulator spring Cap screw Compression nut orifice Bypass tube SECTION 3 SERVICING COMPONENTS Appendix Instructions for All Gas Conversion Kits for Ovens with Wayne Burner Natural Gas to Propane 8 00 IV PILOT ORIFICE CONVERSION Figure 4 1 Unscrew the two 1 2 nuts that secure the gas train to the venturi mounting plate See Figure 4 Unscrew the pilot tube compression nut and slide it out of the way Then pull the tube from the fitting to expose the pilot orifice See Figure 4 Separate the venturi mounting plate and gas train assembly Leave the main orifice holder attached to the gas train piping assembly Remove and discard the existing pilot orifice Slip the kit supplied pilot orifice into the pilot tube With the orifice in place push the tube back into the
163. cases you can upgrade the fan shaft assembly using Service Kit P N 49810 0121 See Part Number Reference on Page 68 for details The following procedures are necessary to align the fan shaft whenever service to the fan shaft or replace ment of the bearings is required REFER TO FIGURE 32 FOR ILLUSTRATIONS OF THE COMPONENTS DE SCRIBED HERE 1 Remove the entire back wall Item 1 of oven to service the fan assembly 2 Remove the blower fan Item 13 and pulley Item 8 NOTE f parts are to be replaced you should replace them now 3 Wheninstalling the Drive Bracket Assembly Item 5 insert one 3 8 flat washer Item 4 at the 4 outer holes and one 3 8 special flat washer Item 14 at the 4 inner holes between bracket and back wall at mounting locations Use eight 3 8 16 x 1 screws Item 2 and assemble a 3 8 lockwasher Item 3 and a 3 8 flat washer Item 4 onto each screw Insert a screw at all 8 locations hand tighten only at this time 4 Install front and rear fan shaft flange bearings Item 10 ifthey were removed to Indirect Drive Bracket Item 6 using three 1 4 20 x 3 4 screws Item 11 and three 1 4 lockwashers Item12 on each bear ing IMPORTANT The bearings 10 must be mounted so the grease fitting faces up when the bracket assembly Item 5 is mounted on the rear wall NOTE Do not tighten flange bearing block screws until Step 10 has been completed 9 Install the fan shaft as shown in Figure
164. ce dure must be followed when replacing the coil or any one contact tube coil and contact tubes will now pull straight out from the base The coil or any individual con tact tube can now be replaced NOTE When replacing the mercury contactor into the oven the wider tube ends must be pointing UP The tubes must ALWAYS be mounted in a vertical position Replace the cover and attach it with the two Phillips head screws Note that the cover and base are marked to show correct orientation 148 SECTION 4 ELECTRICAL WIRING DIAGRAMS SECTION 4 ELECTRICAL WIRING DIAGRAMS COMPONENT WIRING A Temperature Controllers 15 16 L2 L1 Gm 7 brn 19 20 55 6 Dic 5 AL 149 Temperature Controller Digital Display Modulating Gas Valve lon PRESENT STYLE TEMPERATURE CONTROLLER Digital Display EARLY STYLE TEMPERATURE CONTROLLER Dial Face SECTION 4 ELECTRICAL WIRING DIAGRAMS B Ignition Modules Centrifugal Switch 110 VAC Centrifugal Switch 110 VAC GND 24V GNO 124V gt Ignition m b Module 1 27 2 Centrifugal TT 9 Spark Switch 150 Le MV Lyh Pv EARLY STYLE IGNITION MODULE with EARLY STYLE CONTROL VALVE To GasControl Pilot Outlet Valve Terminals EARLY STYLE IGNITION MODULE with PRESENT STYLE CONTROL VA
165. ck Switch 7 Molor Gndil16 Convoyor Spead od neutral wht 16 l Contra Modulo EXIT SP Com Count 45V blk 16 5 Com Count nj v 29 219 Conveyor AC 9 CD iD Cooling Fan Rear interlock Door interlock H H ooling Fan 9 Blowor Switch Switch a Cep qe oe BLOWER CONVEYOR ht tc Switch 1 8 913 4 3 4349 yel 12 4 e 614 as brn Fan Blower anise eee gt Motor Starter N O 650 F AL HEAT bm bin 2 x Pressure n 343 C Switch blu Co Transformer Solenold Cooling Fan Valve Blower Motor botow J See Terminals MV MV red High Limil E M wht i Control Modula Gh n d t N3 650 24 Gnd Pllot bo tt High Limit Burner T T non om Flame iH i Switch ove Sensor In Bui with lamp Module LE 3 Gnd Burner Blower Motor Spark To Hi wiCentrlfugal Control Valve Pilot Swilch Switch Gas Outlet Lamp PS200VL series gas oven with analog temp control 34983 208 240V main blower motor 120V control circuit 208 240V 50 60 Hz 1 Ph 3 pole 4 wire supply 2 hot 1 neutral 1 ground SINVHOVIO ONISIM 0819 NOLLO3S 891
166. co burner see Figure 61 This burner was used on PS360WB70 and PS360EWB ovens only Late production PS360EWB and PS360WB70 ov ens used the Wayne burner shown in Figure 62 In addition many PS360EWB ovens were retrofitted during 1998 to use the Wayne burner Servicing the Midco burner is beyond the scope of this manual However note that most gas train components EXCEPT FOR THE BURNER ITSELF are identical to the components used with the Wayne burner If necessary contact Middleby Tech nical Service for assistance Wayne burner see Figure 62 Wayne burners are used on all Middleby oven models except early production PS360WB70 and PS360EWB models The Wayne burner configuration varies slightly be tween oven models and so may be slightly differ ent from that shown in Figure 62 Refer to the drawings in Part Number Reference Burner Com ponents pages 88 90 for illustrations of the burner configuration used on each oven model Common variants include Flexible airtube between the burner blower and plenum Used on all PS555 570 series ovens 120V burner blower motor Used on PS200 series through 3 02 PS310 PS314 PS360 PS360WB and PS570S ovens e 208 240V line voltage blower motor Used on PS200 series 4 02 or later PS360WB70 PS360EWB PS555 and PS570G ovens Figure 61 Midco burner Burner blower Burner blower motor Plenum Pilot line 92 Solenoid valve vs Modulating valve
167. compression fitting until it bottoms While holding the tube in place slide the compression Compression nut into place Tighten the nut to a snug fit with your nut fingers Orifice Gently tighten the nut one complete turn with a wrench holder DO NOT OVERTIGHTEN THE COMPRESSION NUT Toallowthe main orifice to be replaced donotreassemble the gas train to the venturi and mounting plate at this time orifice MAIN ORIFICE CONVERSION Unscrew the existing main orifice from its holder using 1 2 hex nuts an 11 16 wrench See Figure 4 Install the kit supplied main orifice into the holder REASSEMBLY Check that the pilot assembly is correctly aligned with the venturi as shown in Figure 5 If necessary reposition the pilot assembly Reassemble the venturi and mounting plate to the gas train assembly Replace the two 1 2 hex nuts to hold the assembly together Replace the assembled gas train into the oven Tighten the gas pipe union on the inlet side of the combination gas valve to hold the gas train in place Figure 5 View from side of venturi View from rear of venturi Rear edge of pilot hood is on centerline of venturi Pilot hood 3 8 9 5mm 11 16 17 5mm 122 SECTION 3 SERVICING COMPONENTS Appendix Instructions for All Gas Conversion Kits for Ovens with Wayne Burner Natural Gas to Propane 8 00 INLET PRESSURE CHECK VII GAS LEAK TEST 1
168. connected to the old Air Switch see Fig ure 1 remove and discard the cutoff section Smooth the end of the tubing and make sure that the tubing interior is cleaning not preventing air flow Insert the end of the aluminum tubing about 1 2 to 3 4 range 0 16 42 inch 13 to 19 mm into the kit s flexible plastic tubing A net as shown in Figure 2 B Position the kit s Mounting Bracket used mainly in PS 200 ovens so that the replacement Air Pressure Switch when mounted is near the location of the old Air Switch Mark the locations of the holes for mounting the bracket Drill each hole using a 11 64 4 5mm drill bit Fasten the Mounting Bracket to the oven using the four 10 32 screws and nuts tightening them securely Orange Orange wire Partially unscrew both screws fastening the clear plastic Figure 3 cover of the Air Pressure Switch to allow removal of this Newer Air Pressure Switch cover The cover is removed in Figure 3 showing tubing and wiring connections Insert one 8 32 x 3 4 19mm screw into the lower right mounting hole near the threaded coupling Screw it partially into the lower right threaded hole of the Mounting Bracket Continued on Sheet 2 SECTION 3 SERVICING COMPONENTS 11 Appendix Instructions for Service Kits 35624 and 35625 Air Pressure Switch Replacement Kits 1 97 Air Pressure Switch Replacment p n 35623 Sheet 2 of 2 SERVICE KIT INSTALLATION INSTRUC
169. correct any problem please CON FIRM THAT THERE IS ACTUALLY A PROBLEM It is extremely difficult to tell if an oven is baking unevenly by simply looking at a pizza with ingredients espe cially if the pizza is a large combination type Often the ingredients and toppings themselves can cause an uneven bake The best way to check for an uneven bake is to make a test bake with a consistent predictable product and then read it We recommend using the customer s dough for a pizza product OR a commercially avail able pancake mix for customers with a variety of prod ucts The pancake mix is generally more sensitive to variations in temperature and thus provides more accu rate results than the dough test When interpreting the results of the test consistently uneven baking on the top of the product may indicate a problem with the upper air fingers Likewise consis tently uneven baking on the bottom of the product may indicate a problem with the lower air fingers The most common bake problem is a front to back bake issue This problem occurs when the front of the conveyor belt towards the window receives more heat than the rear or vice versa This results in uneven bak ing for the product based on where it is placed on the conveyor Figure 6 Internal air finger chart 39224 WLDMT PLT OTR 5 13 WIRASD 37000 0577 WLDMT PLATE INNER COL W DAM 42410 0202 ASSY RAISED W SLD BAFFLE 37900 0051 PLATE OUT
170. d should be used on these ovens if possible P N 28071 0027 Fig 1C Digital Temperature Controller with blue plastic face plate operating at 120V on off mode only P N 28071 0028 Fig 1D Digital Temperature Controller with gray rubber face plate and buttons with text operating at 120V on off mode only Figure 1 P N 28071 0028 Fig 1E Digital Temperature Controller with gray rubber face plate and buttons with symbols operating at 120V on off mode only P N 30871 Fig 1E Digital Temperature Controller with gray rubber face plate and buttons with symbols operating at 208 240V on off mode only Used on early PS360WB70 and some CE oven models P N 32571 Fig 1E Digital Temperature Controller with gray rubber face plate and buttons with symbols operating at 208 240V PID mode only Used on early PS360EWB P N 36021 Fig 1F Digital Temperature Controller with gray face plate steel trim on edges operating at 120 240V selectable on off or PID modes P N 36056 Fig 1G Digital Temperature Controller with black plastic face plate operating at 120 240V selectable on off or PID modes Jj Middleby Middleby Marshall am IE en GE SEE Middleby Marshall 27600 SEE WMA Marshall LL Oer TEMP Osp tock ovER TEMP Function
171. d wire is located inside the burner blower motor electrical box containing the 24 volt transformer and prepurge relay The green ground wire is secured by a ring terminal at the base of the transformer and runs from a wire nut which ties the yellow ground lead from the ignitor module with the yellow wire from the transformer and the black wire from the prepurge relay coil is the green wire only that is to be removed When reconnecting the module wires be sure that the yellow wire which is actually the ground wire is connected to the top terminal marked 24v GND on the new module If using existing ignitor sense lead from old module reconnect to new module using adapter See Figures 3 and 4 When new ignitor sense lead becomes available the adapter will longer be needed and the ignitor sensor lead will connect to the new module as called out in Figure 5 REPLACING NEW MODULE WITH OLD WHEN REPLACING A NEW MODULE WITH AN OLD MODULE IT IS MANDATORY TO INSTALL A BURNER TRANSFORMER GROUND WIRE SEE FIGURE 2 Use a green 18 AWG 105 degree C U L listed wire and terminal ring This ground wire should be located inside the burner blower motor electrical box containing the 24 volt transformer and prepurge relay The green ground wire should be secured by a ring terminal at the base of the transformer and run into the wire nut which ties the yellow ground lead from the ignitor module with the yellow wire from the transformer and the bl
172. ds Repeat procedure until troublefree operation is obtained 103 SECTION 3 SERVICING COMPONENTS NO SPARK SYSTEM DOES NOT WORK VISUALLY CHECK That all wire connections on control board and main gas valve are secure No Yes START NOTE If 100 lockout control open heat switch contacts for 60 seconds CORRECT by making connections Close heat switch contacts Spark should be present within 30 seconds N ls 25Vac present across 25V terminals on control board No Yes System was in lockout Is 120Vac present Is control board fuse i 2 ES ony Determine reason for lockout Conduct microamperage test No Yes Replace Open heat switch as outlined in this manual fuse contacts for starting at A in the Peter vine why Replace Pilot lights main valve Primary voltage transformer will not come section is not present Close Heat switch within 10 15 seconds is 3Vac fused control board or 25Vac non fused control board present across terminals MV PV and PV on control board No Yes Replace S86 Turn OFF supply voltage control board Check ignitor senser cable Is it securely connected to the spark transformer No Ye S i not cut brittle burnt or cracked No Yes Yes is spark gap 1 8 and located in pilot gas stream Turn eu Correct or replace pilot burner
173. e 5 19 9 5 LEN Modulating gas blower valve if so equipped Solenoid valve if so equipped Combination gas control valve safety regulator Burner Gas pipe shutoff valve Modulating gas Burner valve if so blower equipped Solenoid valve if so equipped Combination gas control valve safety regulator Pilot pressure Gas pipe tap pilot tee shutoff valve union 126 SECTION 3 SERVICING COMPONENTS Appendix Instructions for All Gas Conversion Kits for Ovens with Wayne Burner Propane to Natural Gas 8 00 PREPARATION AND DISASSEMBLY Turn off the electric power supply to the oven Turn off the gas supply at the service valve behind the oven Open the machinery compartment door Open the union in the gas supply line The union is located on the inlet side of the combination gas control valve See Figure 1 Unscrew the four hex screws that hold the venturi mounting plate to the front of the burner Remove the gas train venturi assembly from the oven COMBINATION GAS CONTROL VALVE SAFETY REGULATOR CONVERSION Remove and discard the following components from the combination gas control valve as shown in Figure 2 e Regulator cap screw e Regulator adjustment screw e Regulator spring Install the stainless steel kit supplied regulator spring with the tapered end facing into the valve as shown in Figure 2 Install the kit supplied regulator adjustment screw
174. e the pilot gas pressure Replace the cap screw and tighten it firmly Pilot Inlet pressure adjustment Measure the current across the pilot flame sensor The tap cap screw current must measure at least 2 0 uA If the current reading is too low recheck the pilot pressure as per Step 7 3 If the pressure reading is correct consult the factory otherwise repeat Steps 7 4 and 7 5 B Main orifice pressure tap MAIN MANIFOLD PRESSURE ADJUSTMENT With the oven set to high flame measure the regulated gas pressure to the burner The outlet pressure should be checked at the main orifice pressure tap See Figure 6 The gas pressure should be 3 W C 7 46mbar for proper operation Pilot pressure If necessary adjust the pressure regulator as follows tap Remove the pressure regulator cap screw Using a screwdriver turn the inner adjustment screw clockwise to increase or counterclockwise to decrease the main burner gas pressure Replace the cap screw and tighten it firmly 8 3 Record the final measured regulated gas pressure on the silver conversion information label included in the kit p n 36857 P Jan 98 Rev B Page 3 of 4 133 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 36856 Gas Conversion Kit for PS360EWB WB70 with Midco Burner Natural Gas to Propane 1 98 CONVERSION LABELING Figure 7 Red LPG label placement Remove and discard the round g
175. e have the customer contact the gas utility supplier 7 PILOT PRESSURE ADJUSTMENT 7 1 Ensure that the air supply is properly adjusted for propane operation Units with a burner blower air shutter see Figure 5 should have the shutter opening at its outside edge set to 5 16 7 94mm A drill bit can be used to check the adjustment of this opening Units without the air shutter see Figure 5 should have the burner air supply adjustment screw turned 11 17 full revolutions clockwise from the fully closed counterclockwise position The screw is located on the front wall of the burner plenum and is surrounded by a MORE AIR label Figure 5 Burner blower configurations Insert a 5 16 Blowers without 7 94 drill y external air shutter opening remove before operation g External air shutter Before proceeding For a PS360EWB oven the set point should be reduced below the room temperature For a PS360WB70 oven set the oven to low flame Figure 6 Gas pressure measurement adjustment locations Measure the pilot pressure at the pilot pressure tap as shown in Figure 6 The gas pressure should be 5 6 W C 12 5 14 9mbar for proper operation Pressure Pilot tube regulator cap connects If necessary adjust the pilot pressure as follows screw here Remove the pilot adjustment cap screw Using a screwdriver turn the inner adjustment screw counterclockwise to increase or clockwise to decreas
176. e motor or blower shaft bearings loose bearings or mo tor mounting bolts or an incorrectly tensioned fan belt Lubricating the blower fan shaft bearings IMPORTANT Middleby uses two different types of grease in blower shaft bearings DuPont Krytox grease is used in some PS536 ovens Refer to Service Bulletin MM 192 included in the Appendices section of this chapter for details on identifying Krytox bearings All other ovens use the standard Middleby high temperature grease P N 17110 0015 Mixing grease types within the bearing will cause the bearing to seize For all PS200 ov ens be sure to use ONLY the standard Middleby grease NOTE Middleby recommends lubricating the blower fan shaft bearings every three months Use a grease gun to lubricate the main blower fan shaft bearings See Figure 28 When lubricating the bear ings Usea high quality NLGI 2 lithium soap grease with petroleum oil such as Middleby P N 17110 0015 Add the grease slowly until a small bead of grease is present atthe seals AVOID OVERGREASING Excessive greasing may cause harmtothe bearing Manually turn the blower shaft by pulling on the belt to purge the grease Wipe off any excess grease The oven cannot be operated until the rear shroud is replaced Blower belt tension NOTE Middleby recommends checking the blower belt condition and tension every three months Check the blower belt for at least 1 25mm def
177. e Switch s clear plastic cover is marked with a o minus sign inside a circle inside the cover Connect the plastic tubing here tube when an Air Pressure Switch is activated by negative pressure for instance the pressure inside the burner blower on these ovens Close the compartment door or pane housing the Air Pressure Switch Confirm that the oven is ready for operation Switch ON the main disconnect switch or the circuit breaker to apply electrical power to the oven Turn on the main gas valve on the gas pipeline Perform a normal oven startup procedure to confirm satisfactory operation SECTION 3 SERVICING COMPONENTS Appendix Instructions to Replace an Alternate Air Switch P N 36194 with Service Kit P N 35624 3 97 p n 36226 Sheet 1 of 2 0397 ALTERNATE AIR PRESSURE SWITCH ADJUSTMENT INSTRUCTIONS For about two weeks in early 1997 our supplier Eclipse Dungs Controls was unable to supply Middleby Marshall with the Blue dial Air Pressure Switch p n 32102 As an alternate to the blue dial Air Switch they sent us the Air Pressure Switch p n 36194 shown in Figure 1 with its clear plastic cover removed The pressure setting adjustment mechanism for this aiter nate Air Pressure Switch is a threaded white plastic cap with a slotted top for screwdriver adjustment Flexible plastic When servicing an oven that has one or more of these alternate Air Pressure Switches operate
178. e amplifier board allowing any setting from 0 100 gas flow All Middleby oven models equipped with a modulating valve use amplifier board P N 31651 Figure 71 Modulating Gas System To transformer 24VAC input orange white blue white 74 Modulating Valve bypass adjustment screw under cap MUST BE FULLY CLOSED To amplifier board terminal 6 To amplifier board terminal 5 Digital Temperature Controller MUST BE SET TO PID OPERATING MODE purple white Amplifier Board PS360EWB with Controller 32571 purple white 4 only SECTION 3 SERVICING COMPONENTS M Combination Gas Control Valve 1 Part Number Reference Combination Gas Valve PS360WB70 PS360EWB ovens are equipped with a 3 4 19 05mm gas line This requires the use of Combination Gas Valve P N 32569 The valve has a tan plastic cover with a blue On Off knob All other oven models are equipped with a 1 2 12 7mm gas line Through 10 01 these ovens used Valve P N 28092 0017 The valve operated on a 60 Hz supply had a tan plastic cover and a blue On Off knob 11 01 and later these ovens use Valve P N 45688 The valve operates on a 50 or 60 Hz supply has a grey plastic cover and a black On Off knob It is otherwise ident
179. e pilot tubing mount points towards the piping assembly Replace the aluminum pilot tubing that was removed in Step 2 2 above Screw in the brass fittings at both ends of the aluminum pilot tubing Tighten them to a snug fit DO NOT OVERTIGHTEN THE FITTINGS MAIN ORIFICE REPLACEMENT Remove and retain the main orifice holder by unscrewing it counterclockwise from the burner plenum wall Unscrew and discard the main orifice from the inner end of the holder as shown in Figure 3 Screw the new natural gas main orifice p n 31821 into the orifice holder Tighten it to a snug fit Replace the main orifice holder into its opening in the burner plenum Tighten it to a snug fit LOW FLAME ORIFICE REPLACEMENT PS360WB70 only Unscrew the brass fittings at both ends of the aluminum low flame tubing This allows the tubing to be removed See Figure 4 Remove and retain the tubing from the solenoid valve Remove and discard the low flame orifice from the end of the low flame tubing Insert the new natural gas low flame orifice p n 22174 0006 into the discharge end of the low flame tubing as shown in Figure 4 Replace the low flame tubing into the fittings on the solenoid valve Screw in the brass fittings at both ends of the aluminum low flame tubing Tighten them to a snug fit GAS LEAK TEST Paint all pipe connections from the gas union to the burner plenum and the aluminum pilot and low flame orifice tubing connections
180. e relays The relays activate the heating elements at 10096 power on a fixed cycle time for a length of time proportional to the signal from the temperature controller Forthis operating mode the temperature controller is set to the PID Mode as described in the Kit instructions Note that temperature controller P N 46837 inc with Service Kit 47321 includes a dedi cated variable pulse mode intended for the PS536 electric oven This special mode is NOT used on the PS555 The temperature controller regulates the cooldown func tion NOTE PS200VL series ovens do not include a cooldown function On most PS200 series and PS300 series gas ovens except the PS200VL the temperature controller moni tors the high limit All other oven models use a High Limit Control Module that is independent of the tem perature controller Part Number Reference Temperature Controllers Middleby Marshall ovens have used several different mod els of temperature controllers The current Digital Tem perature Controller P N 46837 included in Service Kit 47321 is the only model currently available All other controllers P N 28071 0012 A Analog Temperature Controller without high limit and cooldown functions 120V on off mode only P N 28071 0018 A Analog Temperature Controller with high limit and cooldown functions 120V on off mode only P N 34983 B Analog Temperature Controller without high limit and cooldown functions 12
181. e thumbwheel Note that this can Match the measured volt not be done on a digital keypad as switching the conveyor age with those shown on switch OFF will also turn off the display the chart below If the voltage reading is more 1 Checkall connections at the terminals on the conveyor d dul hat th than 5VDC of that shown B 2 u eto iMi t at ie are correct on the chart complete and tight Connections are shown in the drawing the Motor Test on the next Correct the connections if necessary page RED Connections are reversed if BLK conveyor direc tion is reversed 120 supply Thumbwheel DC Motor Voltage gt Wire colors vary Display PS200 PS310 360 by oven model Setting 570 360WB70 360WB 360EWB 3 mins 84VDC 67VDC 4 mins 63VDC 50VDC 5 mins 51VDC 40VDC COM BROWN OR BLACK 6 mins 43VDC 34VDC 7 mins 37VDC 28VDC COUNT YELLOW OR WHITE 5 mins 32000 25000 9 mins 29VDC 22VDC 10 mins 27VDC 20VDC FON ORANGE OR RED 11 mins 24VDC 18VDC 12 mins 22VDC 17VDC 13 mins 19VDC 14VDC 15 mins 18VDC 13VDC 2 Ensure that there is power to the controller Use a digital multimeter to read the voltage between the ter minals marked AC The voltage should read between 110 120VAC 4 Check the magnetic pickup on the motor If the power is not present or of an incorrect voltage check the power source nthe DICKUp Sun qood condition check that the conveyor 15 run
182. e tubing from between the combination gas valve and the burner plate Refer to Figure 1 2 Cut the tubing for installation of the tee as shown in Figure 1 Cut a 3 4 piece out of the pilot line tubing to insert the tee as shown in Figure 1 NOTE The tubing will insert 1 4 into the tee at both ends Replace the pilot tube and tee and tighten all connections Check that there are no kinks in the pilot line Fire the oven and check connections for gas leaks by painting them with rich soap and water solution Bubbles indicate a gas leak gas leak is detected tighten the pipe connection and recheck ior leaks Replace the part s if gas leak cannot be stopped B PILOT PRESSURE REGULATION Using Combination Gas Valve Pilot Adjustment 1 Unscrew the plug from the pilot tee and install a water column gauge To avoid calibration problems do not use a dial face mechanical W C gauge Refer to Figure 1 PS300 Lower Oven for an of water gauge connection 2 Wait until oven is running on low flame in order to adjust pilot pressure Turn the temperature controi set down well below the actual temperature in the oven to maintain low 3 Gain access to the pilot adjustment screw under the screw on combination gas valve as shown in Figure 1 4 Read the water column gauge connected at the tee while tuming the pilot screw adjustment Tuming clock wise decreases pressure and turning counterciockwise increa
183. e used to upgrade either of the two previous controllers to the Watlow version A Part Number Reference High Limit Control Mod ules P N Description 28071 0002 United Electric Type 54 high limit control module No longer available upgrade to current model 34982 using Service Kit 39733 28071 0014 United Electric Type 55 high limit cooldown con trol module No longer available upgrade to current model 34982 using Service Kit 39733 34982 Watlow high limit control module 115V For use on ovens with 120V control circuits 33983 Watlow high limit control module 240V For use on ovens with 208 240V control cir cuits 30693 Illuminated reset button green for Watlow con trol all voltages 39733 High Limit Conversion Kit for PS300 PS310 PS350 and PS360 ovens Replaces P Ns 28071 0002 or 28071 0014 with P N 34982 B Location On ovens that include the separate high limit control mod ule it is located PS200 series Inside the machinery compartment PS360 series Inside the control compartment Early P8555 ovens Inside the left blower motor com partment Current PS555 and all PS570 ovens Inside the machinery compartment 45 SECTION 3 SERVICING COMPONENTS C Operation and Troubleshooting Referto the wiring diagrams at the back of this manual for high limit wiring connections The Watlow high limit control module generally uses a dedi cated high limit thermocouple Some older ovens use a dual function four
184. eckthe inlet pressure atthe inlet pressure tap SeeFigure6 An inlet pressure of 11 14 W C 27 4 34 9mbar is recommended for propane operation If the inlet pressure is HIGHERTHAN 14 W C 34 9mbar This pressure may damage the combination gas control valve safety regulator The gas supply pressure should be decreased LOWER THAN 11 W C 27 4mbar It may be necessary to increase the supplied gas pressure CAUTION IF IT IS NECESSARY TO ADJUST THE GAS LINE PRESSURE HAVE THE CUSTOMER CONTACT THE GAS UTILITY SUPPLIER ENGLISH IX PILOT PRESSURE ADJUSTMENT 1 Unscrew the cap plug from the pilot pressure tap pilot tee and attach amanometer to the tap See Figure 6 Remove the pilot adjustment cap screw from the combination gas control valve Turn the oven on and allow it to heat to temperature Make a note of the customer s set point temperature After the oven has heated adjust the set point of the oven far lower than its current operating temperature This ensures that the pilot flame will be at its lowest level for some time Continued Figure 6 Measure inlet pressure here Measure pilot pressure here under cap plug 123 Adjust manifold pressure here under cap screw Measure manifold pressure here Adjust pilot pressure here under cap screw SECTION 3 SERVICING COMPONENTS e6ed HSITDNA 5 gt 2
185. ed Time of Delivery TOD onveyor Spee Bake Chamber Length Bake Chamber Length Product Diameter Example PS570S Oven 7 00 Bake Time 16 Product Diameter ms y 70 16 8 6 mins 8 36 2 Oven Oven Capacity Hou pa Bake Chamber Length Product Diameter x Bake Chamber Depth x 60 min hr Product Diameter TOD _ 70 16 x 32 Example PS570S Oven 7 00 Bake Time 16 Product Diameter Z2zz 6 98 75 pizzas hr 256 in SECTION 3 SERVICING COMPONENTS SECTION 3 SERVICING COMPONENTS CONVEYOR SPEED CONTROLLER AND DRIVE MOTOR The Conveyor Speed Controller is used to set and monitor the speed of the conveyor The Controller consists of three components Control Module Early units used a module which featured a microcom puter that was unique to each oven model Using this control module required verifying that the correct mi crocomputer was installed Later units use DIP switches to set up the controller for a particular oven model This later model was initially available with a thumbwheel unit either 4 or 8 DIP switches Current models feature a digital display with keypad 8 DIP switches Thumbwheel Unit or Digital Display with Keypad This module displays the conveyor speed and allows it to be adjusted by the operator It is connected to the control module by a ribbon cable Pickup Assembly The pickup assembly consists of a magn
186. electable on off or PID modes P N 46837 G Service Kit P N 47321 Digital Temperature Controller with black plastic face plate 120 240V selectable on off PID and variable pulse modes Note that the dedicated variable pulse mode is used on the PS536 electric oven ONLY Using this mode re quires moving a jumper on one of the PC boards inside the controller The PS555 variable pulse electric oven does NOT use this mode and should have the control ler set to the PID mode as described in the Kit instruc tions Figure 22 Temperature controllers N AMiddleby Marshall Middleby Mme 128 Middleby Marshall 121 Middleby Marshall MMA Marshall _ ALM 12 47 474 47 ILLI crm crgpnntg GEE PL SLI LILI OE SEE Pt SEE Pt zu us Ei OVER TEMP TD goug NE Y n 7 Xs e 2 31 SECTION 3 SERVICING COMPONENTS B Description The temperature controller consists of two main compo nents a sleeve or case metal or plastic with terminal con nections on the back and a plug in chassis that includes the faceplate and circuitry The sleeve is mounted to the panel or door of the oven and the chassis is inserted into the front of the sleeve VERY IMP
187. emperature Controller E Heat Switch Closing the heat switch completes a circuit 1 Through the heat switch 2 Through blower motor centrifugal switch 3 Through the high limit switch 4 For ovens with on On Off heater activation mode To the primary relay contacts of the Temperature Controller terminals 4 and 5 for digital controllers terminals 5 and 6 for analog controllers When the temperature sensing thermocouple s indicate that the oven temperature is below the set point on the Temperature Controller the Tempera ture Controller will energize the contactor s which in turn energize the heaters When the oven temperature reaches the set point ofthe Temperature Controller the Temperature Con troller will cut powerto the heaters When the tem perature drops a few degrees the Temperature Con troller will again energize the heaters An indicator on the Temperature Controller will show whether the Controller is calling for heat This indicator varies by Temperature Controller model Refer to the instructions for the appropriate Tem perature Controller for an illustration and descrip tion of this indicator 5 For ovens with a Variable Pulse heater activation system To terminals 15 and 16 on the tempera ture controller In response to the signal from the thermocouple s Terminals 15 and 16 send a 4 20mA signal to a controller module that contains an amplifier board and two solid state relays The relays
188. en See Figures 37 39 ven gu From inside the oven cavity reach into the blower recess and remove the inlet rings See Figure 40 Loosen the set screw on the blower wheel hub Direction remove the blower wheel A special wheel puller of rotation tool P N 42400 0101 is available for this purpose See Figure 41 Figure 37 Clockwise blower wheel Heat slinger blades face motor IMPORTANT Before installing the new wheel apply an anti seize lubricant Middleby P N 17110 0017 to the motor shaft and the inside of the blower wheel hub Note slant of blades Figure 40 rear view Inlet ring Figure 38 Counterclockwise blower wheel Direction of rotation Heat slinger blades face motor Note slant of blades rear view Figure 41 Figure 39 Blower wheel placement Blower wheel puller tool Shown from rear of oven Counter Clockwise clockwise Upper right Upper left T Clockwise clockwise Lower left Lower right 15 SECTION 3 SERVICING COMPONENTS A PS555 570 series ovens All PS555 570 series ovens are equipped with two 1hp blower motors Each motor indirectly drives a pulley on the shaft of a blower wheel with a fan belt Two main designs exist for the PS555 570 blower fan sys tem PS570 5708 design In this version the pillow block bearings for the blower wheel shaft were mounted up right on brackets t
189. er wheel This means that the pressure applied to the end of the tube is positive Because of this the tube should be connected to the positive side of the switch Ifthe switch is used to detect burner blower opera tion check the type of burner used on the oven The Midco burner used ONLY on some PS360EWB PS360WB70 ovens has its pitot tube mounted inside the blower wheel For correct operation you should attach the tube to the NEGATIVE side of the switch Referto Figure 51 foran illustration of the Midco burner For ovens with the standard Wayne burner the pitot tube is mounted outside the blower wheel For correct operation you should attach the tube to the POSITIVE side of the switch Note that some PS360EWB and PS360WB70 ovens use the Wayne burner You should al ways check the type of burner installed into the oven before connecting the airtube Refer to Figure 52 for an illustration of a typical PS360WB70 EWB gas train with the Wayne burner Figure 52 PS360WB70 EWB with Wayne burner SECTION 3 SERVICING COMPONENTS C Appendices Appendix Instructions for Service Kits 35624 and 35625 Air Pressure Switch Replacement Kits 1 97 p n 35623 Sheet 1 of 2 SERVICE KIT INSTALLATION INSTRUCTIONS ci Air Pressure Switch Replacment Kit Air Pressure Switch Replacement Kit Parts List Kit p n Kit p n 35624 35625 i Part Name Gty Part Number Tubing Air Pressure Switch 1 32102 In per WC 31462 mbars
190. er thermocouples send their signals to Temperature sensing thermocouples for these ov the digital temperature controller The thermocouple sup ens should be installed in the two existing ther plied in this Kit can be used to replace ANY of the thermo mocouple mounting holes couples on these ovens e Refer to Figure 13 Measure and scribe marks in Some 570 ovens are equipped with only two thermo the rear wall of the oven for drilling the high limit couples In these ovens thermocouple mounting hole Make sure that your The thermocouple on the right side of the oven has two measurements begin at the edges of the rear pan leads and sends its signal to the temperature controller els and NOT and the outer edges of the oven The thermocouple on the left side of the oven is a dual Drill the new high limit thermocouple mounting hole function unit It has FOUR LEADS and sends indi using an 11 32 8 73mm D x 8 203mm L bit vidual signals to the temperature controller and the high Be sure to drill through all three walls of the oven limit control module Drill the two screw mounting holes for the high limit Installing this Kit will replace BOTH thermocouples with thermocouple using a 7 64 2 78mm bit Tap the current three lead versions located on the back wall of holes using a 6 32 tap the oven The Kit also requires the installation of a THIRD thermocouple to act as a high limit sensor Be cause of this you will need three separate therm
191. erature swing after preheating is about 5 degrees Fahrenheit above and below the set point IMPORTANT Because the PS200 series elec tric oven uses an on off system for heater acti vation the temperature controller MUST be set to the on off operating mode Refer to Tem perature Controller on Page 30 Early PS200 series ovens used mercury contactors 208 380V ovens used two 3 pole contactors 416 480V ovens used a single 3 pole contactor Six 50A fuses one per element protect the heating circuit See Fig ure 76 Current PS200 series ovens replace the mercury contactors with solid state relays mounted on heat sinks Six relays are used on 208 380V ovens 416 480V ovens use three relays Ovens that use the solid state relays also use 50A circuit breaker blocks in place of the fuses See Figure 77 NOTE All control wire used on these ovens is rated at 221 F 105 C DO NOT replace with lower rated wire Figure 76 PS200 electric early with mercury contactors and fuses Mercury Terminal Fuseblock with 50A fuses Part number reference Solid state Part No Description 27375 0001 Heating element 208V 27375 0002 Heating element 240V 27375 0003 Heating element 380V 28041 0015 Mercury contactor 3 pole 50A 42810 0091 Contactor tube replacement kit inc qty 1 retainer clip P N 27170 0248 42810 0090 Coil replacement kit inc qty 3 re tainer clip P N 27170 0248 28150 01
192. essure tap Pilot orifice See chart on Pilot line Main orifice Combination gas 1 4 aluminum tubing See chart on Page 69 control valve 3 4 15125 0002 Page 69 32569 per foot Figure 57 PS360EWB or PS360WB70 gas train with Wayne burner PS360WB70 ONLY Solenoid valve 3 4 31500 Air tube silicone rubber Air shutter FSJOUEWB ONET 22450 0297 42810 0087 M520 modulating valve 3 4 foot 32570 POSITIVE f Burner blower SIDE OF AIR and motor assy 208 240V 27170 0287 SWITCH Combination gas control valve 3 4 PS360WB70 ONLY Bypass line 1 4 aluminum tubing 3 4 union 15125 0002 23051 0004 per foot Manual shutoff valve 3 4 23115 0010 Pilot Pilot line 1 4 aluminum Pressure tubing tap 15125 0002 30185 89 per foot SECTION 3 SERVICING COMPONENTS Figure 58 PS570S gas train Burner blower and motor assy 120V OVENS RETROFITTED with centrifugal WITH MODUEATING safety switch GAS SYSTEM ONLY 27170 0011 M420 modulating valve 1 2 PEN Flexible air hose 22450 0255 1 2 union 23051 0003 Air shutter 42810 0087 NOT SHOWN Pilot line components are 1 4 aluminum tubing installed on back wall 15125 0002 of machinery per foot compartment 240Vp 120Vs blower motor transformer Combination gas control valve 1 2 Solenoid valve 1 2 456
193. etic wheel on the end of the gear motor conveyor drive motor shaft and a Hall Device sensor that provides feedback to the control module As the magnetic wheel turns the revolutions of the magnet are monitored by the Hall Device sensor The signals are sent to the control module which compares the motor speed with the speed shown on the thumbwheel or digital display The control module in creases or decreases the voltage to the gear motor conveyor drive motor depending on the signal Figure 12 Original style speed controller Produced with thumbwheel only Interchangeable microcomputer selects oven model gt THIS CONTROLLERIS OBSOLETE AND LONGER AVAILABLE Control module Microcomputer Thumbwheel A 1 DIP switches may be on control module or digital display depending on the controller Part Number Reference Speed Controllers Original style speed controller with interchangeable mi crocomputer and thumbwheel This unit is no longer available and part numbers are provided for reference only Servicing this unit is beyond the scope of this manual If this controller is in need of service we ommend simply installing a current unit see below P N Description 28174 0004 5360 controller yellow 12A microcomputer 28074 0006 5360 microcomputer yellow 12A 27170 0232 5360 microcomputer w emulator yellow 12A 28074 0007 5314 controller o
194. ety switch to sense blower operation see Air Pressure Safety Switch on Page 81 This safety feature prevents burner operation in case of motor failure F AirShutter The air shutter is a round metal plate located on the open end of the burner blower wheel Adjusting the position of the shutter will increase or decrease the amount of air that is permitted into the plenum for combustion Rotate the plate in a counterclockwise direction to increase the air supply or in a clockwise direction to reduce the air supply You can insert a drill bit into the shutter gap to check the size ofthe opening Referto Figure 69 forthe recommended opening sizes Early Midco burners use an adjustment screw on the front wall of the plenum to adjust the airflow If it is not possible to adjust the air supply properly using the screw a retrofit kit is available P N 36829 to install the external air shutter shown in Figure 69 SECTION 3 SERVICING COMPONENTS In these cases the pilot may ignite but the main burner gas valve will not be energized It is also possible for drafts or unusual air currents to deflect the pilot flame away from the flame sensor Deflection of the pilot flame may also be caused by main burner ignition con cussion or roll out of the main burner flame An additional point to be considered is the condition of the pilot flame If the pilot flame is hard and blowing the grounding area of the pilot is reduced to a point where the
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196. f wheel faces IN clockwise SRS Left end K ny Counter PS570S PS570G PS555 Clockwise clockwise Open end of wheel faces OUT Left end Right end Li Note slant of blades Figure 46 Bearing lubrication Grease fittings 1 per bearing 4 total PS570 55705 Grease fittings 1 per bearing 4 total 570 555 SECTION 3 SERVICING COMPONENTS 4 Blower belt tension Figure 47 NOTE Middleby recommends checking the blower Blower belt tension and belt condition and tension every three months repositioning the blower motor Check the blower belt for at least 1 25mm deflection at the center and for cracking or excessive wear Overtightening the belt will cause premature bearing failure and possible vibrations See Figure 47 5570 If necessary adjust the tension by loosening 255705 the two motor mounting bolts as shown in Figure 47 Reposition the motor as neccessary until the correct deflection is reached then tighten the bolts 1 25mm 5 Bearing replacement and alignment vertical deflection Whenever service to the blower shaft or replacement of the bearings is required the shaft will need to be aligned NOTE Apply anti seize compound MM P N 17110 0017 to all bolts before installing back wall assembly to oven PS570G First reassemble the back wall components but DO NOT TIGHTEN THE H
197. g to the demand Modulating valves are used on all PS360EWB PS555 and PS570G gas ovens They are also used on PS200 ovens produced 4 02 or later and PS570S ovens produced 9 00 or later The Model PS360EWB oven uses Maxitrol M520 modu lating valve with a 3 4 gas line P N 32570 All other Middleby oven models equipped with a modulating valve use the Maxitrol M420 valve with a 1 2 gas line P N 41647 SECTION 3 SERVICING COMPONENTS The modulating valve features a bypass adjustment screw shown in Figure 71 For all ovens except the PS536 the screw should ALWAYS remain fully closed no adjustment is necessary The screw 15 pre set to the fully closed posi tion from the factory If the screw is adjusted to any setting other than fully closed the oven may not be able to main tain the set point temperature IMPORTANT For proper functioning of the modu lating valve the temperature controller MUST be set to the PID operating mode Refer to Tempera ture Controller on Page 31 L Amplifier Board ovens with a modulating gas valve only Ovens equipped with a modulating gas valve have an ampli fier board mounted inside the machinery compartment In response to the millivolt signal from the thermocouple the Digital Temperature Controller sends a 4 20mA signal to the amplifer board The board in turn passes on a 0 20VDC signal to the modulating valve The valve opens or closes proportionally to the signal from th
198. hat were parallel to the fan belts See Figure 42 PS555 570G design In this version the pillow block bearings are mounted with the grease fittings pointing in towards the center of the oven See Figure 43 The two designs share many common parts including blower wheels motors and bearings From a service standpoint the major difference is the size of the pulleys and the length of the belts Blower motors on all PS555 570 series ovens are rated for 208 240V single phase and are protected by A built in thermal overload protection device Two 15A fuses or 15A circuit breakers Refer to Figure 44 for the location of the fuses breakers In addition each blower fan is protected by an air pressure saftety switch that prevents the burner heating elements from activating if the fan is not rotating See Air Pressure Safety Switch on Page 81 Figure 42 PS570 570S blower configuration Belt Direction of rotation Blower shaft Bearing Pulley Blower wheel inside oven Figure 43 PS555 570G blower configuration Belt Blower motor Pulley Blower shaft Bearing Pulley 5570 5705 15 fuses located left side of machinery compartment 555 early 15A breakers located inside left blower motor compartment Figure 44 Fuse circuit breaker locations gt Blower w
199. he centrifugal switch is not clos ing properly and is either loose or defective For 120V burner blower motors with an internal cen trifugal switch tighten the switch If this fails to correct the problem replace the motor For 208 240V burner blower motors with a separate air pressure safety switch refer to Air Pressure Safety Switch on Page 82 to troubleshoot the switch Relay Connect a voltmeter across the supply terminals on the relay The reading should be 24V If you do not get a 24V reading the transformer should be replaced If 24V is present at the relay and if after 15 to 45 sec onds you do not get 110V or 208 240V as appropri ate on terminal 3 of the relay replace the relay Main Gas Valve and Ignition Module If 24V can be measured across the ignition module supply terminals there should also be 24V between terminals PV and MV PV on the gas control module you have 24V reading the pilot valve should be open and the spark should be on to ignite the pilot gas When the pilot gas has ignited the main burner should ignite If not check MV terminal to ground and see if 24V is present If no voltage is present replace the ignition module is possible to have a pilot on but have the spark continue to try to light the pilot If this continues for more than 30 seconds then it should be assumed that the flame sensor is not working properly This can be easily checked Refer to Control Module Flame Se
200. heel inside oven 555 current 570 15 breakers located B right side of machinery compartment rm SECTION 3 SERVICING COMPONENTS 1 Part number reference Part Number Description Part Number Description 22072 0026 Bearing pillow block 1 25 4mm bore 27381 0069 Motor 1 hp 208 240V 50 60 Hz 1 Ph 2 oT AE 22521 0005 wheel clockwise right of bore PS5708 oo PS570 left end of PS555 PS570S PS570G 35210 0251 Blower shaft 1 dia PS570 22521 0006 Blower wheel counterclockwise 35210 0506 Blowershaft 177 16 dia 55705 of PS570 right end of P8555 55705 41899 Blower shaft 1 7 16 dia PS555 or PS570G 55706 Blower Pulley Motor Pulley Belt Blower Application model Hz PartNo _ Desc PartNo _ Desc PartNo _ Desc RPM Standard PS570 60 22230 0084 BK52 30476 BK47 22181 0037 55705 60 22230 0087 BK47H 30476 BK47 46744 55 1780 55705 50 22230 0087 BK47H 22230 0086 BK55 46745 BX56 1733 RPM PS570G 60 39587 BK70 44977 BK70 46452 BX67 1780 RPM 555 60 39587 BK70 39586 BK80 44946 BX61 2080 RPM 555G 555E Pizza Hut PS570S 60 22230 0087 BK47H 22230 0086 BK55 46745 BX56 1733 RPM USA 55705 60 22230 0087 BK47H 39910 BK62 44963 BX58 2300 RPM High Altitude PS570G 60 39587 BK70 39586 80 46453 68 2057 55706 60 39587 BK70 46455
201. ical to the previous version and may be used to replace it in all cases 2 Valve Operation When the ON OFF knob on the valve is in the ON position gas is allowed to enterthe valve Once 24VAC is supplied to the valve gas is supplied to the pilot line When the pilot flame has been proved see Pilot and Proof of Flame Rectification on Page 94 24VAC is supplied to the combination valve by the ignition module opening the main valve Gas pressure from the inlet side of the valve is passed through the Pressure Regulator The regulated pres sure is supplied to a cavity below the main valve diaphragm This pressure overcomes the spring force and moves the main valve to its open position During operation the main valve is opened and closed by the pressure regulator to keep a constant pressure at the outlet of the valve When power to the valve is cut the cavity below the main valve diaphragm is depressurized and the valve spring closes the main valve rapidly to shut off the main burner When the 24VAC supply to the valve is cut the valve stops gas flow to both the pilot and the main burner The combination valve includes taps to measure both the inlet pressure and the regulated pressure To ensure accu racy the regulated pressure should be measured when the oven is on low flame Servicing the Combination Valve Pilot pressure One of the more common service issues with the com bination valve occurs on ovens with the on off gas
202. ilicone wraps around i thermocouple flange it wraps around the edges of the thermocouple s mounting and onto mounting flange 8 NOTE FOR HIGH LIMIT THERMOCOUPLES PS310 360 electric ovens have two thermocouples inside the machinery compartment One thermocouple is con nected to the temperature controller while the other is Mounting connected to the high limit control module tube The thermocouple supplied in this Kit is incompatible with the early United Electric Type 54 and Type 55 high limit control modules used on these ovens If the oven is equipped with one of these control modules it will be necessary to upgrade the control unit to the current Figure 6 Watlow model shown in Figure 6 before the thermo Thermocouple Wiring PS360 Series couple can be replaced Service Kit 39733 includes all parts and instructions needed for the conversion Refer White 22 to Service Bulletin 168 5 7 99 for details Red Digital Temperature Controller Remove the silicone seal around the end of the thermo couple Loosen the set screw Pull the thermocouple out of its mounting tube Care Shielded fully thread the wiring out of the oven and discard the ground ead LES GJ thermocouple Check that the silicone has been removed completely ite Red from end of the mounting tube An
203. ils to stop the leak replace the affected component and repeat the gas leak test Hidden gas leaks can cause a flashback in the machinery compartment THIS CAN CAUSE SEVERE INJURY OR 1 WARNING FIRE EXPLOSION HAZARD DEATH Stand well clear when switching on the heating circuit 5 3 If no leaks are detected by the test switch on the oven Switch on the heating circuit to ignite the main burner 5 4 With the burner in operation paint all gas pipe joints with the solution of soap and water 5 5 If any further gas leaks are detected shut down the oven Reseal and tighten the affected joints and connections If tightening Page 2 of 4 the connections fails to stop the leak replace the affected component s and repeat the gas leak test 132 P Jan 98 Rev B p n 36857 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 36856 Gas Conversion Kit for PS360EWB WB70 with Midco Burner Natural Gas to Propane 1 98 6 INLET PRESSURE CHECK 6 1 Check the gas control inlet pressure at the inlet pressure tap See Figure 6 An inlet pressure of 6 14 14 9 34 9mbar is recommended for propane operation 6 2 Ifthe inlet pressure is HIGHER THAN 14 W C 34 9mbar This pressure may damage the combination gas control valve Decrease the supplied gas pressure LOWER THAN W C 7 46mbar It may be necessary to increase the supplied gas pressure If itis necessary to adjust the gas line pressur
204. ination free of the terminal Remove the orange wires from the inop erative Air Switch Clip the wire at each spade lug easy on termination where the wire enters the spade lug Insert the orange wires through the coupling hardware of the replacement Air Switch If U blade spade lug terminals are available strip each orange wire properly for that terminal then crimp a U blade terminal on each wire Other wise skip to step 7 Strip the insulation on each wire about 3 8 to 1 2 back from the clipped end of the wire Unscrew the terminal connections on the blue dial Air Pressure Switch Under the rectangular washer of the terminal insert the U blade spade lug if used or wrap the bare wire around the threaded portion of the terminal corresponding to a terminal on the alternate Air Pressure Switch 9 Tighten the screw of each terminal to ensure good electrical connection 10 Arrange the wires within the switch body to ensure adequate clearance and to remain connected when the coupling hardware is positioned for switch cover reinstallation 11 Install and tighten the coupling hardware Avoid any strain on the orange wires 12 Adjust the rim around the blue dial so that the 0 16 value on the rim is aligned with the A symbol on the blue dial 13 Reinstall the switch cover 14 Close the panel or door and restore the oven to normal operating condition Test the new Air Pressure Switch s operation
205. ing If the motor fails any of these tests replace the motor Replacing the Magnetic Pickup If you need to replace the magnetic pickup on a gear motor shaft 1 2 J Apply Loctite Removable 242 or equivalent sparingly to the threads Turn the mounting screw until it is finger tight then turn it an additional 1 4 turn with a wrench Unshielded Pickup Wires on Early PS360 series ovens The conveyor speed controller can be affected by electrical noise transmitted by other electrical components or wiring Early PS360 series ovens used an unshielded connection between the pickup assembly and the control module On these ovens the unshielded wiring can pick up the noise and transmit it to the control module The problem is most easily seen when the conveyor fails during burner spark ignition There are two remedies for this problem Turn the conveyor switch to the OFF position and then back to the ON position after the burner has ignited The controller should reset and allow normal operation This should be used as a stop gap measure ONLY to allow the oven to continue operation Replace the pickup wiring between the control module and the terminal block with a new shielded cable P N 42400 0334 When installing the shielded cable fol low the color code change shown here Old Wiring Shielded Cable Brown Black Orange Red Yellow White Wiring diagrams are also provided in Figures 20 and 21 on the next page
206. ings for the oven type and control version see switch setting instructions in Figure 2 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 42810 0133 Conveyor Speed Controller Kit with Thumbwheel 4 95 D Gear Motor Sprocket Combinations The chart reference below lists the different motor sprocket combinations used with the DIP switch conveyor control system CONVEYOR MOTOR SPROCKET COMBINATIONS MODEL amp CHAMBER GEAR MOTOR CONVEYOR BAKE TIME LENGTH MOTOR SPROCKET SPROCKET PARAMETERS 15 200 40 5 13501 Ratio 10T 2 40 Min to 29 50 Min PS220FS 27384 0011 22151 0003 22151 0002 PS224 Standard PS200T 1350 1 Ratio 10T 2 40 Min to 29 50 Min Tandem 27384 0011 22159 0004 22151 0002 PS2001 Min 40 5 3111 Ratio 15T 10T 40 to 10 Min High Speed 27384 0014 22151 0003 22151 tooo 496 PS200SB 40 5 135011 EX 20T 2 40 Min to 29 50 Min Split Belt 27384 22159 0003 5360 PS310 PS314 1400 1 Ratio 15T 9T PS360SB 27384 0008 22152 0018 22152 0017 2 40 Min to 29 50 Min PS360WB PS350 Standard PS360WB70 70 1400 1 Ratio 157 9T 2 40 Min to 29 50 Min Wide Body Stretch 27384 0008 22152 0018 22152 0017 PS360SS 54 5 1400 1 Ratio 45T 9T 1 Min to 10 Min High Speed 27384 0008 22152 0027 22152 0017 PS360T 1400 1 Ratio 30T 2 40 Min to 29 50 Min Tandem 27384 0008 22152 0022 ee 7 PS570 1400 1 Ratio 15T 2 40
207. ion Control PN 31020 os Obsolete Settings Standard Setting FIGURE 2 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 42810 0133 Conveyor Speed Controller Kit with Thumbwheel 4 95 B Replacement Thumb Wheel Switch Installation 1 Disconnect the power to the conveyor control by turning the conveyor switch to the off position and additionally by turning off the main power disconnect to the oven 2 Remove the two screws that secure the failed switch body to the control door Remove the switch body from the door 3 Locate the ribbon cable connector that links the thumb wheel switch to the controller Note the orienta tion of the cable for replacement Grasp the connector frimly and pull it away from the control 4 The thumb wheel connector is a polarized interlocking type connector that can only be installed in the correct orientation Locate the connector to the terminal strip so that the polarized interlocking lug on the connector is aligned with the mating slot on the terminal and use your thumb to press the connector firmly into the terminal 5 Locate the switch body to the control panel and asssemble the switch body to the panel using the screws from step 2 6 Set the switches on the control to diagnostic mode in Figure 2 7 Run diagnostic tests to determine performance to the control see diagnostic instructions below 8 Set the mode switches back to the correct sett
208. ions on Page 2 for component placement for other oven models ENGLISH Figure 2 Adjustment screw Ny Regulator spring Cap screw Compression nut orifice Bypass tube SECTION 3 SERVICING COMPONENTS Appendix Instructions for All Gas Conversion Kits for Ovens with Wayne Burner Propane to Natural Gas 8 00 IV PILOT ORIFICE CONVERSION Figure 4 1 Unscrew the two 1 2 nuts that secure the gas train to the venturi mounting plate See Figure 4 Unscrew the pilot tube compression nut and slide it out of the way Then pull the tube from the fitting to expose the pilot orifice See Figure 4 Separate the venturi mounting plate and gas train assembly Leave the main orifice holder attached to the gas train piping assembly Remove and discard the existing pilot orifice Slip the kit supplied pilot orifice into the pilot tube With the orifice in place push the tube back into the compression fitting until it bottoms While holding the tube in place slide the compression Compression nut into place Tighten the nut to a snug fit with your nut fingers Orifice Gently tighten the nut one complete turn with a wrench holder DO NOT OVERTIGHTEN THE COMPRESSION NUT Toallowthe main orifice to be replaced donotreassemble the gas train to the venturi and mounting plate at this time orifice MAIN ORIFICE CONVERSION Unscrew the existing main orifice from its holder
209. ive assembly using Kit P N 49810 0121 Part Number Description 22230 0072 Pulley 1 2 12 7mm bore 22071 0019 Bearing 1 2 12 7mm bore flange Direction of rotation mount __ viewed from 37900 0094 Fan shaft alignment tool early 27381 0066 Motor 1 3 hp 200 240V 50 60Hz 1 Ph 22181 0034 Fan belt rear of oven Figure 27 Blower motor fuses Current version components Blower Part Number Description 35900 0232 Shaft blower fan 22230 0073 Pulley 5 8 15 9mm bore 22072 0025 Bearing 5 8 15 9mm bore pillow block mount 27399 0003 Blower fan 16 0 4m diameter E 5 4 37900 0106 Fan shaft alignment tool current fug et 49810 0121 Indirect drive upgrade kit upgrades early style version to current version 49810 0018 Fan shaft service kit includes 2 bear ings 1 shaft and alignment tool 27381 0066 Motor 1 3 hp 200 240V 50 60Hz 1 Ph 22181 0034 Fan belt 2 Blower balancing and direction of rotation Proper blower rotation is extremely important From the rear of the oven the blower shaft pulley should turn in a clockwise direction See Figures 25 and 26 All blower fans are balanced at the factory Any fan found to be out of balance should be replaced Vibra tion from an out of balance fan can cause poor baking and premature bearing failure Note that vibrations can also be caused by other sources including defectiv
210. k wall of the oven Ort bod Install the kit supplied retaining plate P N 41687 as shown in Figure 3 Fasten the attachment plate to the back wall of the ak 4 oven using the two kit supplied 10 16 x 3 4 self tap r y ping screws Ensure that the thermocouple flange is umm securely trapped between the plate and the rear wall of screws 2 the oven Route the wiring through the grommet hole and into the machinery compartment Check that the leads are clear of all components PARTICULARLY THE BLOWER MOTOR by using the existing wiring bundles Figure 4 Thermocouple Wiring PS360 Series Connect the leads as shown in Figure 4 Digital Temperature Controller Attach the kit supplied nylon clamp and 10 16 x 3 4 8 9 screw to the rear of the oven The clamp should be 7 10 positioned to support the thermocouple leads away from the flue pipes and vent openings PS360 Series rear wall thermocouples 2 96 or later serial numbers after ASH 0001 Thermocouples on these ovens are mounted directly to the 1 15 back wall of the oven using a single retaining screw It 16 should be possible to simply replace the existing thermo couple using the original mounting hardware To replace the thermocouple
211. kit supplied 1 4 wire connectors to connect these four wires to the terminals on the lighted reset switch Terminals 1 and 3 Red wires these connections are interchangeable Terminal 2 Black wire Terminal 4 White wire kit supplied 17 Push the lighted reset switch through the mounting hole in the center of the bracket until it snaps into place Be sure to avoid pinching the wires against the sides of the mounting hole Cooldown circuit wiring NOTE Perform steps 18 and 19 ONLY if you are replacing a UE Type 55 controller If you are replacing a UE Type 54 controller which has no cooldown circuit skip ahead to Step 20 18 Attach the oven s existing cooldown wiring to the following terminals on the oven s Temperature Con troller as shown in Figures 7 and 8 For Ovens with a Digital Temperature Controller a Terminal 9 Black wire from blower switch b Terminal 10 Brown wire from blower switch For Ovens with an Analog Temperature Controller a Terminal 13 Black wire from blower switch b Terminal 14 Brown wire from blower switch 19 Attach a brown kit supplied wire between the following terminals on the Temperature Controller Digital Controller Terminals 10 and L1 Analog Controller Terminals 13 and L1 High Limit Control wiring 20 Using the kit supplied 1 4 wire connectors wire the high limit control terminals as follows a Terminal NO Purple wire originally to UE control Terminal
212. l be necessary to replace the entire speed controller with a current model SECTION 3 SERVICING COMPONENTS 2 IF THE GEAR MOTOR WILL NOT RUN AT ALL Is thumbwheel or digital display set to 0 00 Set speed to Check for 120VAC customer to Speed Controller specification All wiring between Controller Magnetic Pickup and Motor in good condition DC voltage is Repair wire present across connection ARM and ARM terminals on Speed Controller Current version Original version with DIP switches with Check that DIP interchangeable switch settings are microcomputer correct for oven Replace model microcomputer Motor still will not run gt Correct DIP switch Ces settings Complete the Conveyor Motor Test Page 19 d NOTE Middleby no longer stocks parts for the original speed controller with inter changeable microcomputer If it is necessary to replace this version of Motor still will not run Replace conveyor the controller or the microcomputer Speed controller and the service agent does not have the parts in stock it will be necessary to replace the entire speed controller with a current model 17 SECTION 3 SERVICING COMPONENTS F Initial Troubleshooting 3 With the AC power on NOTE When changing the conveyor speed on a controller check the DC voltage to with a thumbwheel it is advisable to the conveyor switch the conveyor motor OFF before adjusting th
213. learance to 50mm ge 1 38 allow door to close gt Reset switch bracket Leave at least 3 75mm front clearance to allow door to close Two 0 187 5mm dia mounting holes BE 5 7 60 S g Figure 5 Figure 6 Base of thermocouple is pushed in to end Thermocouple of the mounting tube Hole in sleeve is next to base of thermocouple Set screw extends through mounting tube and sleeve Page 3 of 8 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 39733 High Limit Conversion Kit for PS300 310 350 amp 360 Ovens 5 99 C WIRING For the various wiring connections listed below cut the kit supplied 18 AWG wires to length Refer to Figures 7 and 8 on pages 6 and 7 for diagrams of the wiring connections Lighted Reset Switch Wiring and Installation 14 Using the kit supplied 1 4 wire connectors connect the following kit supplied wires Red wires connect one wire to each RESET terminal on the high limit control Black wire connect to terminal on the high limit control White wire connect to terminal L2 on the oven s temperature controller 15 Slip the free ends of these four wires through the circular hole in the reset switch mounting bracket so that they hang down in front of the control compartment 16 Use the
214. lection at the center and for cracking or excessive wear Overtightening the belt will cause premature bearing failure and possible vibrations See Figure 29 If necessary adjust the tension of the belt by loosening the two motor mounting bolts as shown in Figure 30 Reposition the motor as neccessary until the correct deflection is reached then tighten the bolts 69 SECTION 3 SERVICING COMPONENTS Figure 28 Bearing lubrication Grease fittings 1 per bearing 2 total Figure 29 Blower belt tension 1 25mm amp vertical gt deflection Figure 30 Repositioning the blower motor Loosen bolts to reposition motor and adjust belt tension SECTION 3 SERVICING COMPONENTS 5 Early style PS200 bearing replacement and alignment NOTE This procedure is for early style indirect fan shaft assemblies only as shown in Figure 25 Bearing replacement procedures for the current style indirect fan shaft assembly Figure 26 are provided on Page 72 IMPORTANT Before attempting any repair on the early style PS200 Indirect Fan Drive Assembly f you need to perform any maintenance more involved than replacing and aligning the shaft bear ings you should upgrade the fan shaft assembly to the current version Check the front and rear brackets Item 6 in Fig ure 32 If the brackets ARE NOT welded to gether you should upgrade the fan shaft assem bly to the current version In either of these
215. limit control module to shut down the burner Note that the high limit control will need to be reset afterthe open is corrected before the oven can re turn to operation 2 Checking the thermocouple with DC millivolt meter It is possible to check that a thermocouple is reading accurately by using a multimeter set to read DC milli volts At 32 F 0 C the thermocouple should read 0 mVDC This can be checked by inserting the ther SECTION 3 SERVICING COMPONENTS mocouple into an ice bath for several minutes At 72 F 22 C the reading should be 1 134mVDC You can use the chart below by checking the tempera ture at the thermocouple s junction terminals This is called the Junction Temperature Figure 24 Thermocouple millivolt readings at various operating and junction temperatures 200 F 250 F 200 325 F 350 400 F 425 F 450 500 F 5502 600 204 C 218 C 260 C 288 C 315 C aoe 41266 vas v5 aor ere sss sos sss 735 vzo ea e open on pos penes 60 F 16 C 10 24 11 01 11 78 ZOn xHOZzCe gt 55 SECTION 3 SERVICING COMPONENTS D Appendices Appendix Instructions for Service Kits 33984 and 33985 Oven Thermocouple Kit 11 01 7724 Middleby Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 USA
216. mocouple Wiring PS536 Digital Temperature Controller in place 8 9 7 10 6 11 E L1 15 16 Shielded ground lead High Limit Control Module Red White Shielded ground lead db TC RESET SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kits 33984 and 33985 Oven Thermocouple Kit 11 01 PS555 Gas thermocouples with screw ter minal connections no terminal blocks Thermocouples on these ovens are located on the rear wall They are secured in place by two screws that are inserted through the holes in the thermocouple flange These ovens are equipped with a three lead flanged thermocouple iden tical to the one in this Kit NOTE FOR HIGH LIMIT THERMOCOUPLES These ovens have a high limit thermocouple installed in the last mounting hole at the exit end of the oven The thermocouple supplied in this Kit can be used to replace ANY of the temperature sensing or high limit ther mocouples on the oven Remove the rear shrouds and blower motor covers This allows access to the thermocouples on the rear wall and screw terminals inside the blower motor compart ments Remove the screws that hold the thermocouple to the wall Slide
217. n also be caused by other sources including defective motor or blower shaft bearings loose bearings or motor mounting bolts or an incorrectly tensioned fan belt Lubricating the blower shaft bearings IMPORTANT Middleby uses two different types of grease in blower shaft bearings DuPont Krytox grease is used in some PS536 ovens Refer to Service Bulletin MM 192 included in the Appendices section of this chapter for details on identifying Krytox bearings All other ovens use the standard Middleby high temperature grease P N 17110 0015 Mixing grease types within the bearing will cause the bearing to seize For all PS555 570 series ovens be sure to use ONLY the stan dard Middleby grease NOTE Middleby recommends lubricating the blower fan shaft bearings every three months Use grease gun to lubricate the main blower fan shaft bearings See Figure 46 When lubricating the bear ings Usea high quality NLGI 2 lithium soap grease with petroleum oil such as Middleby P N 17110 0015 Add the grease slowly until a small bead of grease is present atthe seals AVOID OVERGREASING Excessive greasing may cause harmtothe bearing Manually turn the blower shaft by pulling on the belt to purge the grease Wipe off any excess grease The oven cannot be operated until the rear shroud is replaced 78 Figure 45 PS500 series blower wheel orientation Clockwise 5570 Counter Right end Open end o
218. nal PS200 Series 2 96 or later serial numbers after ASH 0001 connections no terminal blocks 5 8 5360 Series rear wall thermocouples before 2 96 serial 5555 Electric and 5555 numbers before ASH 0001 PS570 X01 X05 name plate ID numbers and PS570S 5360 Series rear wall thermocouples 2 96 or later serial early with side mounted thermocouples inside or outside numbers after ASH 0001 the blower motor compartments 55705 late rear wall thermocouples with left side AND right side terminal block connections PS555G and PS570G rear wall thermocouples with left side terminal block connections 5360 Series front mounted thermocouples inside the machinery compartment WARNING BEFORE PERFORMING ANY SERVICE WORK THE ELECTRICAL POWER SUPPLY AND THE GAS SUPPLY MUST BE TURNED OFF 1 P N 34701 Rev V1 11 01 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kits 33984 and 33985 Oven Thermocouple Kit 11 01 PS200 Series before 2 96 serial numbers before ASH 0001 Thermocouples on these ovens are located inside the ma chinery compartment They are secured in place by a set screw in the mounting tube inside the plenum chamber This Kit eliminates the set screw The new thermocouple is held in place by the head of the screw that is already used to attach the mounting tube NOTE FOR HIGH LIMIT THERMOCOUPLES CE ovens and PS200VL models have two thermocouples one mounted above the
219. nd blower fan The panel should be kept upright as shown in Figure 78 Remove the fan shroud Remove the screws at both ends of the element and pull the element straight out See Figure 79 When replacing the rear oven panel be sure to use a high temperature never seize lubricant on the 12 bolts that hold the panel in place Figure 79 Removing elements Mounting screws SECTION 3 SERVICING COMPONENTS B PS310 360 series ovens 1 Description of heating system All PS310 360 series electric ovens use an on off sys tem for heater activation When the oven demands heat the temperature controller activates mercury contactors that in turn activate the heaters at 100 power The contactors open when the temperature rises to 2 degrees above the set point and close when the oven s temperature falls 2 degrees Fahrenheit below the set point Because of residual heat within the oven however the temperature swing after preheating is about 5 degrees Fahrenheit above and below the set point IMPORTANT Because the PS310 360 series electric oven uses an on off system for heater activation the temperature controller MUST be set to the on off operating mode Refer to Temperature Controller on Page 30 Each bank of heaters 3 total uses one mercury contactor and three fuses 30A fuses were used through 1 91 Heat inside the machinery compartment can de rate these fuses causing the fuse to blow pre maturely
220. ning and then check the volt age between the and x5VDC terminals on the controller On controllers with thumb wheels the voltage should read 5VDC 0 3VDC Digital con trollers should read 5VDC 1 0VDC Next check the voltage between the COM and COUNT terminals The reading should stay be tween 2 and 3VDC If EITHER of these two readings are incorrect perform the Conveyor Control Pickup Test on the next page 18 Conveyor Control Pickup Test Visually check the pickup for the following magnet is clean and the bearing is in good condition There are no chips or cracks on the magnet e If using a PS350 style pickup see Figure 14 there is a 1 64 to 1 32 0 4 0 8mm or a business card thickness gap between magnet and hall device Setthe multimeter to the VDC scale then connect the meter probes as shown in Figure 19 The black com mon probe should connect to the COM terminal on the speed control board while the red VQ probe connects to the 5V terminal 5 0 should be present at all times when the conveyor is operating e If 5VDC is present proceed to Step 3 f 5VDC is not present disconnect the three pickup wires connected the SIGNAL and 5 terminals and again check for 5VDC f 5VDC is present with the pickup discon nected replace the pickup assembly f 5VDC is still not present replace the
221. nometer check the pressure the manifold pressure tap as shown in Figure 6 A manifold pressure of 3 1 2 W C 8 7mbar is recommended for natural gas operation Adjust the pressure as necessary by turning the adjustment screw on the combination gas control valve Turning the screw clockwise decreases the pressure Turning the screw counter clockwise increases the pressure If the manifold pressure cannot be properly adjusted switch the oven off and allow it to cool then replace the combination gas control valve Repeat Section VII Gas Leak Test before attempting to adjust the manifold pressure again After the manifold pressure has been properly adjusted replace the cap screw Record the final value on the Gas Conversion Label as shown in Figure 8 Switch the oven off and allow it to cool MARKING AND LABELING Printthe word NATURAL in the space provided on the Gas Control Conversion Tag P N 22501 0007 See Figure 8 Fasten the tag onto the gas piping next to the combination gas control valve Locate the round LPG label red on the burner or burner motor Attach the kit supplied yellow green label P N 22500 0064 on top of the LPG label The new label should completely cover the LPG label See Figure 8 Complete the information on the Gas Conversion Label as shown in Figure 8 Attach the Gas Conversion Label in plain view on the outside of the oven as close as possilble to
222. not be equipped with a pilot pressure tap If you en counter problems with an erratic pilot see Servicing the Combination Valve on Page 98 it may be neces sary to install a tap Middleby offers Service Kit P N 30185 which includes the pilot pressure tap and in structions A copy of the instructions are also provided in the Appendices section IMPORTANT older oven that has a pilot pressure tap installed should have the combination gas valve re placed with a current version at the same time Com bination valves used priorto 1994 are beyond the scope of this Manual and may not be compatible with the tap SECTION 3 SERVICING COMPONENTS R Troubleshooting Flowcharts INTERMITTENT PILOT SYSTEM TROUBLESHOOTING TABLE startup and checkout procedure Turn thermostat controller to call for heat Check line voltage power low voltage transformer thermostat controller and wiring Turn gas supply off Pull ignition lead and check spark at control board ignition stud Spark okay YES Power to 25Vac nominal Spark across igniter senser gap YES Check fuse fused model only Replace if necessary Replace control board if fuse okay eCheck ignition cable ground wiring ceramic insulator and gap and correct if necessary Check boot of the ignition cable for signs of melting or buckling take protective action to shield cable and boot from excessive
223. ns 5 99 zi Middleby 7728 Marshall High Limit Conversion Kit for PS300 310 350 amp 360 Ovens KIT COMPONENTS Check that the kit includes ALL of these parts BEFORE you begin Qty 1 39732 1 34982 1 30693 1 1 Description Instructions Watlow high limit control module Reset switch w lighted pushbutton Mounting bracket reset switch Wire set reset switch includes 4 wires and 3 1 4 25mm connectors Thermocouple type J 6 152 4 Mounting sleeve thermocouple 35634 35691 1 33812 1 1 39690 TOOLS REQUIRED Drill with 3 16 drill bit Middleby Marshall Thermocouple Signal Source Generator P N 27170 0192 Wire cutters strippers A OVERVIEW This Service Kit is used to replace two different types of United Electric high limit cooldown controllers with a Watlow high limit controller for PS300 310 350 and 360 Ovens See Figure 1 The early Type 54 United Electric control was ONLY equipped with a high limit circuit Ovens equipped with this control did NOT have a cooldown circuit This control was used on the following models 5300 350 Gas early PS300 310 350 360 Electric early all voltages For these ovens the kit directly replaces the Type 54 high limit control with the Watlow high limit con trol The later Type 55 United Electric control was equipped with BOTH high limit and cooldown circuits and was used on the following models PS300 310 350 360 Electric
224. nsor Test on the next page A reading of 2 0 uA or greater should be obtained poor reading is obtained the pilot flame and sensor are probably not making good contact This will keep the main valve from opening Refer to the section on flame rectification If the microamp reading is good and 24V cannot be obtained at terminal MV then the ignition module should be replaced Burner Operation a Shut off the manual gas valve for oven Turn the Burner and Heat switches ON The spark should begin at the pilot burner within 30 seconds With the manual gas valve turned off no gas will be present so the spark will continue for the lockout timing period of 90 seconds b Turn the Heat switch OFF then turn on the gas supply Set the temperature controller set point above the actual oven temperature c Turnthe Heat switch ON The system should start as follows Spark turns on and pilot gas valve opens at once Pilot burner ignites after gas reaches the pilot burner Spark cuts off when pilot is established e Main gas valve opens and main burner lights after gas reaches the burner ports NOTE Main burner flame may not be satisfactory until the gas input and combustion air have been adjusted Check Grounding Electrical ground connections must be clean and tight If the lead wire is damaged or deteriorated use only No 14 to 18 gauge moisture resistant thermoplastic insulated wire with a 221 F 105
225. nt pickup assembly side view BRACKET CLAMP MAGNET MOTOR D Controller Motor Failure When the conveyor speed controller fails it is very pos sible that a shorted conveyor motor caused the problem Unless the motor is changed the installation of another conveyor speed controller will simply burn up the new con troller You are STRONGLY ADVISED to bypass the speed con troller and install the tester unit shown in Figure 18 before replacing any speed controller that has burned out This will identify the source of the problem the speed controller or the motor It is much less expensive to burn out the tester than another speed controller The components for this tester can be purchased at any electrical supply store The tester is not as accurate or sensitive as the speed controller and so should NOT be left in place on the oven after servicing ASSEMBLY MOTOR SHAFT SECTION 3 SERVICING COMPONENTS Figure 17 Current pickup assembly end view SENSOR BODY MAGNET ASSEMBLY Components needed for the field tester Full wave AC DC bridge 400V 4A Light dimmer switch In line 5AAC fuse enclosed in plastic case 2alligator clips CAUTION DO NOT turn the conveyor switch ON while the field tester is connected 1 Disconnectthe motor lead wires and attach to the field tester as shown in Figure 18 Depending on the oven model you can simply use the black and red gear motor
226. o couple kits for these ovens If necessary remove the end plugs and air fingers from the oven to access the areas around the new high limit thermocouple mounting hole Vacuum out ALL drill shavings If the oven is Remove the rear shrouds and open the blower motor equipped with a screen over the openings for the compartment doors This allows access to the ther lower air fingers use a flexible hose extension on mocouples on the rear wall and terminal blocks in the vacuum to reach the shavings through the up side the blower motor compartments per air finger openings Reinstall the air fingers and end plugs onto the oven Figure 13 Location of High Limit Thermocouple Mounting Hole PS570S High limit thermocouple High limit thermocouple position for ovens with position for ovens with LEFT TO RIGHT conveyors RIGHT TO LEFT conveyors e 127 RA a 3 1 2 lt 89mm 3 8 lt 9 5 NZ N N N 41 32 dia 7 64 dia SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kits 33984 and 33985 Oven Thermocouple Kit 11 01 Figure 14a Thermocouple Wiring PS570S Late Left to Right Conveyor Left Ground White Red White Ground Red White Right Terminal leads temp temp temp temp leads hilim hi lim Terminal Block
227. o 7 16 hex bolts the clamps that hold the adjustment rod in place Inserta 2 Phillips head screwdriver into the hole in the rod as shown in Figure 53 Swing the handle of the screwdriver to rotate the rod and move the flame gate You should position the gate as far as possible towards the EXIT end of the conveyor as shown Remove the screwdriver Tighten the two screws to hold the clamps in place 5570 5705 flame gate adjustment LEFT TO RIGHT conveyor travel factory setting RIGHT TO LEFT conveyor travel factory setting 22222741 222222222000 Gate points to RIGHT exit end of oven Metal clamps hold rod in place 7 16 hex bolts 2 Rotate screwdriver handle to reposition flame gate Gate points to LEFT exit end of oven SECTION 3 SERVICING COMPONENTS X GAS TRAIN AND BURNER SYSTEM Figure 54 A Part Number Reference PS200 series gas train Gas Train Components a Burner blower and motor assy OVENS WITH ON OFF OVENS WITH MODULATING GAS SYSTEM ONLY M420 modulating valve 1 2 GAS SYSTEM ONLY 120V motor assy with centrifugal safety switch 27170 0011 OVENS WITH MODULATING GAS SYSTEM ONLY 208 240V motor assy 27170 0287 OVENS WITH ON OFF GAS SYSTEM ONLY Junction box Includes 240Vp 120
228. o Burner Propane to Natural Gas 1 98 6 INLET PRESSURE CHECK 6 1 Check the gas control inlet pressure at the inlet pressure tap See Figure 6 An inlet pressure of 6 14 14 9 34 9mbar is recommended for natural gas operation 6 2 If the inlet pressure is HIGHER THAN 14 W 34 9mbar This pressure may damage the combination gas control valve Decrease the supplied gas pressure LOWER THAN W C 7 46mbar It may be necessary to increase the supplied gas pressure If itis necessary to adjust the gas line pressure have the customer contact the gas utility supplier 7 PILOT PRESSURE ADJUSTMENT 7 1 Ensure that the main burner primary air supply is properly adjusted for natural gas operation Units with a burner blower air shutter see Figure 5 should have the shutter opening at its outside edge set to 5 16 7 94mm A drill bit can be used to check the adjustment of this opening Units without the air shutter see Figure 5 should have the burner air supply adjustment screw turned 11 17 full revolutions clockwise from the fully closed counterclockwise position The screw is located on the front wall of the burner plenum and is surrounded by a MORE AIR label Figure 5 Y Burner blower configurations Insert a 5 16 Blowers without 7 94 drill y to Ep external air shutter opening remove before operation External air Before proceeding For a PS360EWB oven the set point should be
229. o exit out of the holes across the width of the conveyor See Figure 8 Before adjusting the shutters it is necessary to deter mine if the finger is providing a balanced air delivery across the width of the conveyor This is the purpose of making a test to read the bake Remove all upper air fingers from the oven NOTE As the air fingers are removed use a felt pen to mark all parts of the fingers This includes the mani fold inner plate and outer plate If a blank or choke plate is used mark that plate also Fingers are marked in the order shown below as viewed from the front of the oven If there are upper and lower oven cavities you should mark the fingers for the upper oven with a U and those for the lower oven with L VERY IMPORTANT When the ovens were shipped from the factory all of the shutters were pre ad justed for their location within the oven parts of the fingers must be marked as explained above and reassembled into their original position Check the size of the openings at the front of the shut ter plates by inserting a drill into the opening The factory setting is a 46 drill 0 081 2 06mm Drill out the four 1 8 pop rivets that are located toward the front of the fingers See Figure 8 NOTE DO NOT drill out the rivet at the back of the air finger This is the pivot for the shutter If the product is lighter at the front of the oven increase the opening by 1 16 1 59mm Ifthe
230. om each end of the oven as necessary to access the thermocouple mounting tubes Remove the rear shrouds Open the blower motor com partment doors Remove the cooling fans from both blower motors Then remove the blower belts For each thermocouple Disconnect the thermocouple leads from the ter minal block inside the blower motor compartment Remove and discard the screws that hold the ther mocouple mounting tube to the plenum wall Re move and discard the thermocouple and tube Plug the internal and external openings left by the tubes using a high temperature silicone sealant If the thermocouples were located outside the blower motor compartments replace the thermocouple cov ers 7 Referto Figure 11 Measure and scribe marks in the rear wall of the oven for drilling the thermocouple mount ing holes Make sure that your measurements begin atthe edges of the rear panels and NOT at the outer edges of the oven Note that there are two different thermocouple placement locations one for Pizza Hut and Pizza Hut International or Tricon ovens and one for all other ovens Drill the new thermocouple mounting holes using an 11 32 8 73mm D x 8 203mm L bit Make sure that you drill through all three walls of the oven Drill the two screw mounting holes for each thermo couple using a 7 64 2 78mm bit Tap the holes using 6 32 tap If necessary remove air fingers from the oven to ac cess the areas a
231. om the leading edge of the product entering the bake chamberto the leading edge of the product leaving the bake chamber See Figure 9 Figure 9 Conveyor Speed Bake Time Conveyor Speed lt Bake Time gt gt C Direction of c Conveyor Travel Leading edge of product B Belt Time Belt Time is a measurement used by several custom ers Itis a trailing edge to trailing edge measurement That is it is the elapsed time from the trailing edge of the product entering the bake chamber to the trailing edge of the product leaving the bake chamber See Figure 10 Note that belt time is equal in length to conveyor speed bake time although the time is measured during a different period of the baking process Time of Delivery TOD Time of delivery TOD is a leading edge fo trailing edge measurement That is it is the elapsed time from when the leading edge of the product enters the bake cham berto when the trailing edge of the product leaves the bake chamber See Figure 11 Figure 10 Belt Time Belt Time lt gt Direction of Trailing edge of product Figure 11 Time of Delivery lt Time of Delivery gt Direction of Conveyor Travel Leading edge of product Trailing edge of product D Formulas for Determining Time of Delivery TOD and Oven Capacity per Hour 1 Time of Delivery TOD Spe
232. on the temperature controller sends a signal to the amplifier board which in turn controls the operation of the modulating valve This allows a modulated gas flow of any necessary value from 0 100 in response for the need for heat to maintain the set point The tem perature controller has no effect on oven ignition Forthis operating mode the temperature controller is set to the PID Mode as described in the Kit instructions Onelectric ovens with On Off heater activation includ ing most PS200 series and PS360 series electric ov ens the temperature controller permits or cuts power to the heating elements as necessary to maintain the set point temperature 30 OFF OFF ON E OFF 2 9 8 8BLZ9OGVECL 360 HIGH SPEED 45T MTR SPRKT 1400 1 MTR 1 10 min 360WB70 570 1400 1 MTR 3 30 OFF ON a a 8SLZ9OGVECHL 98 9S98vtc Lk 536 9 3 RPM 1 10 555 1400 1 MTR 4 30 Forthis operating mode the temperature controller is set to the On Off Mode as described in the Kit instructions On electric ovens with variable pulse heater activation including PS555 electric ovens the temperature con troller sends its signal to a controller module that con tains an amplifier board and two solid stat
233. ons are based on input from thermocouples When two wires composed of dissimilar metals are joined together and one of the ends is heated a continuous current flow is generated Middleby ovens use a Type J iron constant thermocouple The iron wire increases the number of dissimilar metal junctions in the circuit Middleby has used several types of thermocouples All can be replaced with the current version Refer to Figure 24 for illustrations two lead thermocouple with a small retaining clip Used for EITHER temperature sensing OR high limit functions This type is no longer available four lead thermocouple with a small retaining clip This is a dual function unit that sends its signal to the temperature controller and to a Separate high limit con trol module This type is no longer available three lead thermocouple with a separate ground lead a shielded cable and a large mounting flange This is the only type of thermocouple available from Middleby at this time If it is used to replace a four lead dual function thermocouple two complete and separate ther mocouples will have to be installed Thermocouple Functions 1 Temperature sensing thermocouple s All thermocouples monitor oven temperature However Middleby uses the term temperature sensing thermo couple in reference to thermocouples that send their signal to the temperature controller instead of to a sepa rate high limit control module On
234. ons for Service Kit 47321 Digital Temperature Controller Kit 2 02 Check that the new controller is mounted into its sleeve Then slide the assembly into the opening in the panel from the outside Check that the controller is upright with the display on top and the keypad on the bottom Locate the rectangular holes on the top and bottom of the new controller s sleeve Attach the two kit supplied mounting brackets against the inside panel of the oven and into the holes in the sleeve as shown in Figure 3 Check that the heads of the screws point to the rear of the controller 7 Tighten the two screws evenly until the lip of the sleeve is seated tightly against the panel Ifthere is a protective clear plastic strip on top of the display remove it at this time Figure 3 Temperature controller is pre installed into sleeve and is upright Control panel Bracket clips and screw heads point to REAR of controller Electrical Connections Wire the new controller as follows If you are replacing an Analog Temperature Controller P Ns 28071 0012 or 28071 0018 see Fig 1A refer to Figure 4A for a listing of the new terminal numbers If you are replacing an Analog Temperature Controller P N 34983 Fig 1B PS200VL models only refer to Figure 4B for a listing of the new terminal numbers If you are replacing any Digital Temperature Controller simply reconnect ALL of the original wires and jumpers to the
235. opening on the oven front panel The ribbon cable from the Thumb Wheel is connected to the 14 connector on the control module Terminals on the specific control are arranged and marked to show electrical connections See Figure 1 Consult the specific oven model wire schernatic for further wiring details especially for magnetic pick up wire color codes The oven application must be selected by setting the DIP switches on the specific control to the proper positions The LED is used for diagnostics DC Motor DC Motor From 120 VAC Power No Connect COM Connect COUNT b 8 Position DIP Switch p PN 28074 0018 PN 31020 FIGURE 1 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 42810 0133 Conveyor Speed Controller Kit with Thumbwheel 4 95 DIP SWITCH SETTINGS FOR BOTH CONTROLS Control PN 28074 0018 REV Standard Conveyor Speed Settings High Speed Option Conveyor Settings m MODEL S OVEN TIMES MIN IMAX 2 s MODEL S OVEN TIME MIN MAX 7 PS200 40 SEC TO 10 MIN 5200 20 1 30 MIN 10 MIN x jo x 1 MIN TO 10 MIN x 2 40 MIN TO 29 50 MIN PS570 SB HIGH SPEED OPT 55705 5 1 30 TO 10 MIN x 5570 PS570S 2 40 MIN TO 29 50 MIN PS350WB7O ee 4 30 MIN TO 30 MIN 5705 58 5224 2 40 MIN 29 50 MIN PS200T Switches All In Open Posit
236. orming this work assumes responsibility for this conversion This kit consists of the following parts Qty Units p n Description ea 36857 Instructions for Conversion of Natural Gas Operation to Propane Operation PS360EWB and PS360WB70 ea 31819 Orifice Pilot Assembly Propane 0 025 0 64mm ea 31822 Orifice Main Propane 0 185 4 70mm ea 22174 0009 Orifice Low Flame Propane 0 034 0 86mm 62 drill used for converting PS360WB70 only ea 22500 0065 Label LPG Red ea 22500 0123 Label Conversion Gas IMPORTANT When converting any oven that is installed at an altitude above 5000 ft 1524 consult Middleby before installing this Kit 1 PREPARATION 1 1 Turn off the electric power supply to the oven 1 2 Turn off the gas supply at the service valve behind the oven WARNING AN Before performing any service or conversion work the electrical power supply AND the gas supply MUST be turned off 1 3 Open the machinery compartment access door 2 PILOT ORIFICE REPLACEMENT 2 1 Unscrew the brass fittings at both ends of the aluminum pilot tubing that connects the pilot orifice to the combination gas control valve This allows the tubing to be removed See Figure 1 Figure 1 Conversion component locations Solenoid valve PS360WB70 only Low flame bypass PS360WB70 only Combination gas control valve Pilot orifice Aluminum pilot tubing p n 36857 P Jan 98 Rev B Page 1 of 4
237. otline 1 800 238 8444 4 4 1 P N 44757 Rev 1 2 02 SECTION 3 SERVICING COMPONENTS Appendix Service Bulletin MM 189 New Conveyor Gear Motors Brushes and Pickup Clamps 8 01 Bulletin MM 189 Date 8 24 01 Middleby Cooking Systems Group uh Toastmaster CTX 1400 Toastmaster Drive Elgin IL 60120 9272 U S A Telephone 847 741 3300 Service and Parts Fax 847 741 4406 7774 Middleby Marshall Service Bulletin SUBJECT New conveyor gear motors brushes and pickup clamps for Middleby Marshall ovens GENERAL The conveyor gear motors used on all Middleby Marshall ovens except model PS536 have been redesigned by the vendor Changes to the motors include smaller diameter motor casing New motor brushes Old style motors continue to use brush P Ns 22450 0052 or 22450 0230 as shown the table below A All of the new motors use brush P N 46658 A shorter clamp to attach the pickup assembly This accommodates the smaller diameter of the motor The pickup assembly with the original clamp is still available as P N 27170 0263 This kit is only available in limited quantities After our stock of the old style pickup assembly kit is exhausted you will need to save the existing clamp to attach a new pickup assembly to an old style motor The pickup assembly with the new shorter clamp is available as P N 46451 All of the new motors will be shipped in
238. ounting screw To ground controller To temperature To ground for high limit terminal on temp controller terminal on temp control module controller controller instead of the two sets 5 Install the new thermocouple into its mounting hole If you will be replacing additional thermocouples re Fasten it in place with the supplied 6 x 3 8 screws peat Steps 2 6 as necessary Wire the thermocouple as shown in Figure 14 The Use the kit supplied nylon clamp and 10 16 x 3 4 thermocouples should be wired to the terminal block Screw to secure the thermocouple leads so that they inside the blower motor compartment closest to the Will clear the shrouds blower belts and pulleys thermocouple Close the machinery compartment and blower motor IMPORTANT compartment doors Replace all shrouds onto the oven As you wire the thermocouples check that ground leads Figure 15 run from the terminal blocks inside the blower motor com Alternate ground lead wiring partments to BOTH the temperature controller AND the Use ONLY if ground leads to front compartment are not present high limit control module as shown in Figure 14 White Red Ground White Red If the ground leads to the front compartment of the oven hi lim hilim leads all temp temp are NOT present for example on an oven that previ
239. out from changes This SET PT setpoint setting can only be Light changed by service Lights when the set personnel WI Middieb point is shown in the l y display ZA arshall C HEAT ON PT ACTUAL TEMP X ACTUAL Light TE V TEMP Lights when the OVERTEMP Light Lights when the oven temperature is greater Actual Tempera than 650 F 343 C GO 2227 t OVER TEMP the display Temperature Key Service Key Press this key once to fa For use by ser view the Actual Tem vice personnel perature in the Dis only play Unlock Key Set Point Key Press this key together Press this key together with the Set Point Key with the Unlock Key to to allow the Set Point Up Arrow and Down Arrow allow the Set Point to to be changed Changes Keys be changed can only be made for Press these keys to adjust Changes can only be 60 seconds the Set Point up or down made for 60 seconds the Set Point will not change refer to Set Point Key and Unlock Key SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 47321 Digital Temperature Controller Kit 2 02 LEY Middleby Marshall Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin IL 60120 847 741 3300 FAX 847 741 4406 Middleby Corporation Service Hotline 1 800 238 8444 SECTION 3 SERVICING COMPONENTS Appendix Service Bulletin MM 136 Electrical
240. partment They are secured in place by a sheet metal screw that traps the thermocouple flange against the wall of the compartment See Figure 7 NOTE FOR HIGH LIMIT THERMOCOUPLES PS536 ovens have two thermocouples one mounted above the other The upper thermocouple senses the oven temperature and is connected to the temperature controller The lower thermocouple is connected to the high limit control module Either thermocouple can be replaced using this Kit Loosen the sheet metal screw that holds the thermo couple flange to the wall of the machinery compart ment Pull the thermocouple out of the machinery compart ment Disconnect the thermocouple leads Install the new thermocouple so that its flange fits firmly against the wall of the machinery compartment Tighten the sheet metal screw so that its head holds the ther mocouple flange securely in place NOTE PS536 ovens do not use a thermocouple mount ing tube so it is CRITICAL that the thermocouple flange is securely fastened to the wall of the machinery com partment Route the thermocouple leads away from the ignition cable Connect the leads as shown in Figure 8 Figure 7 Thermocouple Installation PS536 Thermocouple Thermocouple flange Mm Temperature sensing thermocouple Machinery compartment wall High limit thermocouple Screw head holds thermocouple flange Figure 8 Ther
241. product is darker atthe front of the oven decrease the opening by 1 16 1 59mm The best way to check the size of the openings is to use numbered drills as a gauge An orifice drill set is ideal for making this adjustment For example to in crease the opening by 1 16 you would use a 30 drill 0 1285 3 26mm which is approximately 1 16 larger than the original setting measured with the 46 drill 0 081 2 06m m Be sure that the measurement is taken at the largest SECTION 2 AIR FLOW AND HEAT TRANSFER point of the opening See Figure 8 While holding the new adjustment clamp the two shut ter plates together two pairs of vice grip pliers are ideal and drill holes for new pop rivets NOTE Most of the old rivet holes can be reused if the old hole is simply elongated However if the hole is not properly elongated the new rivets may pull the plates out of adjustment when they are installed IMPORTANT Aluminum 1 8 pop rivets are ideal for use here They are much easier to drill out than stainless steel rivets Repeat these steps to adjust all upper air fingers Then reinstall the fingers into the oven Perform another test bake IMPORTANT This test bake must be an exact dupli cate of the first test bake If you change any of the conditions you will change the results Ifthe test indicates an even bake your adjustment is complete Ifthe test indicates that the bake is still uneven you will need to
242. r baking and premature motor bearing fail ure Note that vibrations can also be caused by other sources including defective motor bearings and loose motor mounting bolts 74 Figure 35 Blower motor fuses single phase motors Left motor Right motor fuses 9A fuses 9A O Control fuse 5A a fel ol of jo Ae A m Ex T E o Figure 36 Blower motor fuses three phase motors Left motor Right motor fuses 5A fuses 5A Control fuse 5A L la 1 5 Transformer fuses 480V electric ovens only SECTION 3 SERVICING COMPONENTS 3 Direction of blower rotation 4 Removing the blower wheels Proper blower rotation is extremely important Blower To change a motor or blower wheel the wheel must rotation is determined by viewing the motor and wheel first be removed from inside the oven as follows from the REAR of the motor or from the open end of Remove the end plugs and conveyor assembly the ov
243. racked If the reading still is unsteady it may be necessary to adjust the pilot pressure Refer to Pilot Pres sure under Servicing the Combination Valve on Page 98 8 System Troubleshooting Start the system by setting the temperature controller above room temperature and observe the system re sponse Establish the type of system malfunction or deviation from normal operation by using the ntermittent Pilot System Troubleshooting Table on Page 103 Use the table by following the questions in the boxes If the condition is true answers yes go down to the next box If the condition is not true answers no go to the box alongside Continue checking and answering conditions in each box until a problem and or the repair is explained Use the Component Checks section as necessary to per form system checks After any maintenance or repair the troubleshooting sequence should be repeated until the procedure ends with normal system operation Figure 75 Voltage Checks for Ignition Module and Combination Gas Valve Ignition Module Voltage Test Points Marked Fused Nonfused MV PV to PV 3 VAC 24 VAC MV PV to MV 12 VAC 24 VAC Combination Gas Valve TR to TH 12 VAC 24 VAC TH TR to TR 3 VAC 24 VAC NOTE Information on the fused ignition module is provided for reference only All ovens produced 19868 or later use the nonfused module The fused module is no longer available SECTION 3 SERVICING COMPONENTS 9
244. range 13A microcomputer 28074 0008 5314 microcomputer orange 13A 27170 0233 5314 microcomputer w emulator orange 13A 28074 0013 5200 microcomputer pink 15A Current style speed controller with either 4 or 8 DIP switch settings and thumbwheel This unit is no longer available from the factory but may still be stocked by service agen cies P N Description 42810 0133 Controller assembly with thumbwheel 42810 0118 Thumbwheel only Current style speed controller with 8 DIP switch set tings and digital display keypad Note that the two types of controllers ARE NOT compatible the controller and display unit MUST be of the same type P N Description 37337 Controller assembly with digital display keypad NCC 8 00 current 37503 Digital display keypad unit only NCC 45133 Controller assembly with digital display keypad Danaher 2 02 current Figure 13 Current style speed controller Produced with Thumbwheel or digital display 4 or 8 DIP switches select oven model Cover plate shows DIP switch settings Thumbwheel or digital display model Control module SECTION 3 SERVICING COMPONENTS B 1 Part Number Reference Pickup Assemblies PS350 style pickup assembly or old style pickup as sembly see Figures 14 15 These parts use the same part number They are no longer available from the factory but may still be stocked by some service agen cies P N Description 28074 0005
245. re pressure to break through the burr Back the screw out until the top of the screw is level with the top of the access hole Turn the adjustment screw back down to adjust the pressure Repeat these steps until the burr is cleared Figure 72 Combination Gas Control Valve Pressure regulator adjustment under cap screw Inlet pressure tap On Off knob should remain in ON position Regulated pressure tap Pilot line connection Pilot pressure adjustment under cap screw Ignition Module Part Number Reference Ignition Module PS360WB70 and PS360EWB ovens equipped with the Midco burner use Ignition Module P N 31501 For all other oven models Through 10 90 these ovens used Ignition Module P N 27161 0004 Some versions of this module included a separate replaceable fuse This mod ule shared a common ground with the 24V trans former and the relay coil See Figure 73 11 90 or later these ovens use Ignition Module P N 27161 0005 included in Service Kit 42810 0114 The module is internally grounded and the common ground with the transformer and relay coil has been eliminated See Figure 74 SECTION 3 SERVICING COMPONENTS If you are replacing the obsolete module P N 27161 0004 with the current version P N 27161 0005 BE SURE TO DISCONNECT THE MODULE FROM THE COMMON GROUND WITH THE TRANSFORMER AND RELAY Double grounding of the module creates a feed
246. read microamps mA is necessary to verify that the proper amount of current is being main tained through the pilot flame The minimum value required is 2 0mA Rectification based ignition sys tems respond in less than 0 8 of a second to a loss of flame If the minimum signal is not being maintained at all times OR if the pilot flame is briefly directed away from the flame sensor or pilot tip the main gas valve may cycle rapidly chattering or the burner may be prevented from activating Other conditions that can cause the failure of the main burner to activate OR chattering of the burner are 1 Pilot flame is too small 2 Gas pressure is too low for proper pilot flame im pingement on the flame sensor E Burner Blower Motor The burner blower motor is located on the side or top of the burner housing Some blowers use a flexible tube to con nect the blower to the burner depending on the available space inside the machinery compartment The burner blower motor drives a blower wheel located in a housing attached to the end of the motor that is the primary air supply for combustion The motor requires no lubrication Depending on the oven model the burner motor operates on either 120V or 208 240V line voltage 120V motors have an internal centrifugal switch that controls the 24V power supply to the gas valve see Burner Blower Motor Centrifugal Safety Switch on Page 80 208 240V motors use a separate air pressure saf
247. reen NAT label from the on burner housing front face of the burner plenum Apply the round red LPG label p n 22500 0065 to the front face of the burner housing as shown in Figure 7 Close the machinery compartment access door Record the information requested on the silver conversion information label Figure 8 shows a representation of this label Apply the conversion information label to the front of the machinery compartment access door next to the control panel Upper oven Lower oven See Figure 9 label location label location Figure 8 Conversion information label Signature of technician Date of conversion performing conversion THIS APPLIANCE HAS BEEN CONVERTED ON TO _ PROPANE GAS WITH KIT NO 36856 BY WHO ACCEPTS THE RESPONSIBILITY FOR THE CORRECTNESS OF THIS CONVERSION MODEL NO MAIN BURNER ORIFICE SIZE H857 2 70mm MANIFOLD PRESSURE __ INPUT RATING 175 000 BTU MAXIMUM INLET PRESSURES 14 W C 34 9mbar Stated on the Measured value oven s data plate recorded in Step 8 3 Figure 9 Conversion information label placement PS360EWB placement PS360WB70 placement Page 4 of 4 Jan 98 Rev p n 36857 134 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 36863 Gas Conversion Kit for PS360EWB WB70 with Midco Burner Propane to Natural Gas 1 98 Fy Middleby Middleby Cooking Systems Group 1400 Toas
248. regu lating system with a solenoid valve when the oven is on low flame During low flame the servo can bounce inside the valve as it searches forthe proper level The bouncing line pressure can also cause surges in the pilot pressure A properly adjusted pilot will tend to smooth out the surges The best way to check for a properly adjusted pilot is to check the pilot line pressure This requires a pilot pressure tap in the pilot line Ovens built 3 94 or later should have the tap installed in the line The tap is also available as Service Kit P N 30185 which includes installation instructions Recommended pilot gas pressures are Wayne burner natural gas 372 4 W C 8 71 9 95 mbar Wayne burner propane 8 10 W C 19 9 24 9 mbar Midco burner all gases 5 6 W C 12 5 14 9 mbar Burrs in pilot adjustment portal Some combination valves have been shown to have shipped with small burrs in the pilot adjustment portal Although this will not interfere with proper operation of the valve in any way it does make it difficult to adjust the pilot pressure until the burr is removed Check for a burr by attaching a manometer to the pilot pressure tap If the manometer does not detect any change in pilot pressure when the screw is tightened all the way down there is probably a burr in the portal To remove a burr perform the following procedure Turn the adjustment screw all the way down A Apply mo
249. repeat the adjustment procedure until an even bake is obtained By keeping the tests identical you should be able to determine how much more the shutter plates should be opened or closed to achieve a balanced bake without re moving the fingers for a third time VERY IMPORTANT After attaining a proper adjust ment of the fingers each air finger should be marked with a metal stamp showing its position inside the oven This will eliminate future problems of operators mixing the adjusted fingers when cleaning the oven Figure 8 PS300 350 style air finger with adjustable shutter plate Higher pressure at the front of the fingers is regulated by the shutter openings 11 Insert drill bit to check size Pivot DO NOT of opening drill out Drill out rivets SECTION 2 AIR FLOW AND HEAT TRANSFER IV OVEN CAPACITY Oven capacity is generally not a service issue However when reporting a Service problem customers may use terms relating to capacity such as bake time belt time time of delivery etc This information is provided as a reference for understanding these terms A Conveyor Speed and Bake Time Middleby Marshall conveyor ovens display the Conveyor Speed on the Thumbwheel or on the display of the Digital Speed Controller as appropriate for the oven model Conveyor Speed is also called Bake Time Conveyor Speed Bake Time is a leading edge to lead ing edge measurement That is it is the elapsed time fr
250. rmit troubleshooting Closing the control cabinet door will reset the switch 1 Closing the door switch permits a circuit to go through a fuse or circuit breaker as appropriate for the oven model to one side of the conveyor switch blower motor switch cooldown relay and heat switch 2 Closing the door switch permits a circuit to go through the motor fuse two 9A or 15A fuses per motor Conveyor Switch Closing the conveyor switch permits a circuit to go to the Conveyor Speed Control Module which 1 Sends power to the gear motor conveyor drive mo tor The 120VAC signal to the Conveyor Speed Control Module is rectified to a 9OVDC signal which is then sent to the gear motor 2 Allows regulation of conveyor speed Adjusting the thumbwheel or digital pushbutton display unit as appropriate to the desired conveyor belt speed in structs the Conveyor Speed Control Module to regu late the output to the gear motor This increases or decreases the conveyor speed as necessary to match the speed setting shown on the thumbwheel or display unit Closing the blower switch energizes 1 The cooling axial fan s 2 The blower motor contactor s Closing this contactor starts the blower motor s When both blower motors are up to speed centrifugal switches located inside the blower motors or air switches de tecting blower operation as appropriate for the oven model will close setting up the heat circuit 3 The Temper
251. round Right temp temp lead Terminal Terminal hi lim hi lim leads all temp temp NS 0 Block 1 nf IER n Block Sis SG oldo 9 ii New chassis A ground wire To high limit To temperature control module controller To temperature controller SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kits 33984 and 33985 Oven Thermocouple Kit 11 01 55705 late rear wall thermocouples with 2 Remove the screws that hold the thermocouple to the left side AND right side terminal block connec wall Slide the thermocouple out of its mounting hole tions Disconnect thermocouple leads Remove and dis card the thermocouple Thermocouples on these ovens are located on the rear wall p and are secured in place by two screws that are inserted Perform Step 4 ONLY if you are installing a high through the holes in the thermocouple flange limit thermocouple and no mounting hole is Most of these ovens have either three or four thermocouples present This would be the case if the oven for all installed in the back wall of the oven The thermocouple merly used a four lead thermocouple to send a at the extreme exit end of the oven is the high limit thermo signal to the high limit control module couple while all oth
252. round the new thermocouple mount ing holes Vacuum outALL drill shavings If the oven is equipped with a screen over the openings for the lower air fin gers use a flexible hose extension on the vacuum to reach the shavings through the upper air finger open ings Reinstall the air fingers and end plugs onto the oven Install the three new thermocouples into the back wall ofthe oven Check that the thermocouple flanges are flush with the back wall Secure each thermocouple in place with the two kit supplied 6 x 3 8 screws Wire the thermocouples as shown in Figure 12 The thermocouples should be wired to the terminal block inside the blower motor compartment closest to the thermocouple IMPORTANT As you wire the thermocouples be sure to connect a single chassis ground wire to the mounting screw for the terminal block See Figure 12 A good ground connection for the thermocouple s uninsulated lead is REQUIRED for proper operation If you will be replacing additional thermocouples re peat Steps 7 15 as necessary Using the kit supplied nylon clamps and 10 16 x 3 4 Screws secure the thermocouple leads to the back wall of the oven so that they will clear the shrouds blower belts and pulleys Replace the blower belts and cooling fans Close the blower motor compartment doors Replace all shrouds onto the oven SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kits 3398
253. rred through surface con tact Such as pizza dough in contact with a pan Radiation Heat is transferred from light colored ob jects to dark colored objects The darker the color of an object the greater the amount of heat that it ab sorbs The lighter the color of an object the greater the amount of heat that it reflects Middleby ovens use light colored interiors aluminized or stainless steel depending on the oven model to reflect as much heat as possible to the product Convection Heated air will transfer heat to objects with which it comes into contact Unless the air flow is controlled hot air will rise and be replaced by cooler air Middleby Marshall ovens use blowers one or two large fans depending on the oven model to force air through adjustable air fingers onto the product The intensity of the heat at the point at which it is sensed is called temperature The difference in temperature between the food product and the heat source that is the pan oven interior or heated air as described above determines the speed at which the heat flows The greater the differ ence in temperature the faster the heat flows to the prod uct In Middleby Marshall conveyor ovens the heat transfer from conduction is greatly dependent on the customer s product and cooking surface pans etc Likewise the heat trans fer from radiation is effectively constant because the color of the oven interior cannot be changed
254. rve the same cautions as in Step 10 Check Spark Igni tion Circuit above If the arc is correct replace the ignitor sensor If the arc is less than it should be disconnect the igni tion cable and use a jumper wire from the ignition mod ule stud terminal If the spark is normal replace the ignition cable If the arc is still smaller than normal replace the ignition module Q Checking the Gas Pressures All gas pressures should be checked using a manometer at the supplied pressure taps as follows 102 Inlet pressure can be checked at the inlet pressure tap on the combination gas valve See Figure 72 on Page 98 Regulated pressure can be checked at the outlet pres sure tap on the combination gas valve See Figure 72 on Page 98 Current PS555 570 series ovens provide an additional regulated pressure tap in the main gas line just before the line enters the burner This allows you to connect a SECOND manometer downstream of the modulating valve to check that the valve is functioning properly We encourage you to use this tap to diagnose prob lems with the modulating valve whenever possible Pilot gas pressure can be checked at the pilot pres sure tap For ovens with a Wayne burner the tap is located on the pilot line For PS360EWB WB70 ovens with a Midco burner the tap is located on the end of the pilot orifice fitting Referto the illustrations on Pages 88 90 Some older ovens pre 1994 with Wayne burners may
255. s not necessary on ovens with a 120V burner blower motor SECTION 3 SERVICING COMPONENTS because of the presence of a centrifugal air switch inside the motor housing see Section VII Burner Blower Motor Centrifugal Safety Switch on the previous page The switch is an assembly that includes a normally open microswitch and a diaphragm When the blower is at speed pressure is applied to the diaphragm which in turn closes the microswitch This completes the heat circuit allowing the burner heating elements to activate If a blower is not operating the microswitch receives no signal from the diaphragm and cannot close preventing burner heating element activation A PartNumber Reference Air Switches Middleby has used four different types of air switches for these applications See Figure 50 When replacing one of these switches note that the cur rent Yamatake Honeywell air switch 4 below cannot be used as an upgrade for an older switch If you are replacing Switches 1 42 or 3 as shown in Figure 50 you should use the Service Kits described for Switch 2 Figure 50 Air pressure safety switch models 1 Original style round air switch Replace with 2 Positive pressure Adjustment screw Normally Normally Closed Open Common Dungs square case replacement air switch with screw adjustment Replace with 2 Adjustment screw Positive pressure Negative pressure 81 2
256. s Control Valve 98 Ignition Module Gas Conversion Kits P Burner and Gas Train Troubleshooting 100 Checking the Gas 102 Troubleshooting Flowcharts 2 103 Intermittent Pilot System Troubleshooting Table 103 No Spark System Does Not 104 Spark is Present Pilot Will Not Light 105 Pilot Lights Valve Will Not Come 106 5 2c ne abes aieo 107 Instructions for Service Kit 42810 0117 Pilot Ignitor Kit 7 91 0 107 Instructions for Service Kit 30185 Pilot Tee 3 94 108 Instructions for Service Kit 42810 0121 Combination Gas Valve 1 92 112 Instructions for Service Kit 42810 0114 Ignition Module 11 90 116 Position of Combination Gas Valve Components during Burner Operation 4 02 118 Instructions for All Gas Conversion Kits for Ovens with Wayne Burner Natural Gas to Propane 8 00 119 Instructions for All Gas Conversion Kits for Ovens with Wayne Burner Propane to Natural Gas 8 00 125 Instructions for Service Kit
257. se To Gas Control High Flame Pilot Outlet Solenoid Valve w PS310 314 360 360WB gas oven with digital temp control 208 240V main blower motor 120V control circuit 208 240V 50 60 Hz 1 Ph 3 pole 4 wire supply 2 hot 1 neutral 1 ground SINVHOVIO ONISIM 0819 NOLLO3S 9 zb 1 bik L1 12 60 HZ m 1 09 NOTE ALL WIRES ARE TO B E 18 AWG UNLESS OTHERWIS SPECIFIED 14 5 10 red bik Door Switch 10A 2NO DC bik 3 4 red Cooling Fan Left aute Fit D B 119 Heat Coll Blower Motar Bwitch Cootdown TC 200 F 82 High Limit Switch 343 N Burner NO 11 120 org org Du Temperature 1 Controller 55 7 56 AbLopL TC 1 A Mo T C righ Flame Bolenold Valve PS360WB70 gas oven with Midco burner and solenoid valve 208 240V main blower motor and control circuit 208 240V 50 60 Hz 1 Ph 2 pole 3 wire supply 2 hot 1 ground SINVHOVIO ONISIM TVOIH LO3 13 NOLLO3S 69 blu ray s Conveyor Speed Block bm gt Speed Control i a 5 Thumbwheel Two Speed Controls i 3 ternal blocks Molors and 5 5 5 Pick ranslormer
258. se to increase or counterclockwise to decrease the main burner gas pressure Replace the cap screw and tighten it firmly 8 3 Record the final measured regulated gas pressure on the silver conversion information label included in the kit p n 36862 P Jan 98 Rev B Page 3 of 4 137 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 36863 Gas Conversion Kit for PS360EWB WB70 with Midco Burner Propane to Natural Gas 1 98 CONVERSION LABELING Figure 7 Yellow NAT label placement Remove and discard the round red LPG label from the front on burner housing face of the burner plenum Apply the round green NAT label p n 22500 0064 to the ACD front face of the burner housing as shown in Figure 7 Close the machinery compartment access door Record the information requested on the silver conversion information label Figure 8 shows a representation of this label Apply the conversion information label to the front of the machinery compartment access door next to the control panel Upper oven Lower oven See Figure 9 label location label location Figure 8 Conversion information label Signature of technician Date of conversion performing conversion THIS APPLIANCE HAS BEEN CONVERTED ON _ NATURAL GAS WITH KIT NO 36863 BY WHO ACCEPTS THE RESPONSIBILITY FOR THE CORRECTNESS OF THIS CONVERSION MODEL NO MAIN BURNER ORIFICE SIZE 234 5 94
259. ses pressure NOTE Some combination gas valves may have burrs in the pilot adjustment portal The pilot of these valves i difficult to adjust unless you break through the burr If the water column gauge does not register any change after the adjustment screw has been tumed all the way down then apply more torque to break through the burr back the screw until the top of the screw is flush with the top of the access hole and turn the screw down again This must be repeated several times Adjust the pilot line pressure as follows If oven is running on NATURAL GAS adjust pilot pressure to 3 5 4 0 WC if oven is running on PROPANE GAS adjust pilot pressure to 8 0 10 0 WC 5 Replace screw over pilot adjustment screw 109 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 30185 Pilot Tee 3 94 Pilot Adjustment Under Screw Combination Gas Valve lt E 7 Pilot Line Tubing Plug Remove Date Tee Check Pressure Code With W C Gauge Combination Series PS200 Plug Remove To Check Pressure With W C Gauge Line Adjustment T Under Screw ubing Series PS300 Upper Ovens Pilot Combination Adjustment Gas Valve Under Tee Remove Plug Check Pressure With W C Gauge 1 1 Water Column Gauge Attached bids bo dta lb 2 2 8 Line Tubing Plug Remove Series PS300 Lower Ovens To Check Pressure With W
260. sional drawing on the front panel of the oven that shows the cor rect air finger configuration as shown in Fig ure 5 Other ovens may have this information on a laminated card attached to the oven Internal air finger chart Middleby ovens have a chart similar to the one shown in Figure 6 attached inside the machinery compartment door Note that if the air finger configuration has been updated since the oven was installed this chart may no longer be correct there 15 no label present on the oven and the chart inside the machinery compartment is in correct contact Middleby Technical Service for assistance Figure 5 3D air finger label if present NOTE Labels of this type are not used on all ovens Label placement and design will vary based on customer preference SECTION 2 AIR FLOW AND HEAT TRANSFER 2 Check that the bake time and temperature settings of the oven match the customer s specifications Most customers have an acceptable range for bake time and temperature to allow for local variations in altitude humidity etc 3 If these checks fail to correct the problem you should perform a test bake to pinpoint the type of baking problem that is present C Performing a Test Bake Before you attempt to
261. stud terminal This is a very high voltage circuit and electrical shock can result Perform the test im mediately upon energizing the system before the ignition module enters safety lockout and inter rupts the spark circuit Check Spark Ignitor If the troubleshooting procedure indicates a problem with the ignitor sensor check the spark ignitor and the ignition cable connections and continuity as follows Check Ignitor Sensor a Check the ignitor spark gap to make certain it is correct 1 8 3 2mm f necessary use a needlenose pliers and carefully bend the tip of the outer electrode to the correct gap b Checkthat the pilot flame is properly adjusted Check Igniton Cable a The ignition cable must not touch metal surfaces or current carrying wires Use ceramic standoff insulators if necessary b Checkthe length of the ignition cable It must not exceed 3 ft 0 9 m c Checkthe connections to the ignitor and ignition module terminals All connections must be clean and tight Loose connections may not conduct a flame current even though the ignition spark is sat isfactory Check the electrical continuity of the cable Replace the cable if it is damaged or dete riorated d spark or a weak spark occurs but the spark ignition circuit checked normally disconnect the ignition cable at the ignitor sensor and measure the arc from the cable end to the ignitor stud Fol low the same general procedures and obse
262. t Secure the bracket to the panel using the kit supplied 6 32 x 1 4 screws and 6 32 nuts DO NOT INSTALL THE RESET SWITCH INTO THE BRACKET AT THIS TIME Insert the kit supplied thermocouple into its mounting sleeve Position the sleeve so that the mounting hole is at the base of the thermocouple not the tip See Figure 5 Insert the thermocouple and mounting sleeve into the original mounting tube The set screw opening in the sleeve should align with the set screw hole on the side of the mounting tube Push the thermocouple into the opening until its base seats firmly on the mount See Figure 6 Insert the thermocouple s set screw into the hole on the side of the mounting tube Tighten the set screw to hold the thermocouple and sleeve in place Thread the thermocouple s shielded cable into the electrical compartment Coil the free end of the cable and fasten it with the kit supplied nylon wire tie Be sure to leave enough free cable to reach the new high limit control Page 2 of 8 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 39733 High Limit Conversion Kit for PS300 310 350 amp 360 Ovens 5 99 Figure 2 High limit thermocouple location lower oven v x High limit thermocouple location upper oven Figure 3 Figure 4 NOT TO SCALE High limit control Leave at least 1 25mm 276 front c
263. t 221 F 105 C DO NOT replace with lower rated wire 2 Partnumber reference Part No Description 43337 Heating element assembly 208V 44525 Heating element assembly 230V 44526 Heating element assembly 380V 44527 Heating element assembly 480V 44914 Controller module 208 230 240V ovens 44568 Controller module 380 480V ovens 35018 Circuit breaker block 50A 3 pole 144 Supply Ovens have a 208V 220 240V 380V or 480VAC elec trical supply The control current of the oven operates at 208 240V 208V and 240V ovens use a 3 wire system 4 wire in cluding the ground connection The control circuit op erates at line voltage 380V and 480V ovens use a 4 wire system 5 wire in cluding the ground connection The 4th neutral wire is utilized to split the incoming 3 phase legs and obtain a separate control circuit at 208 240V Heater specifications PS555 electric ovens use 12 heating elements in 4 assemblies 3 elements per assembly Elements CANNOT be removed from the assembly If one element is not functioning properly the entire as sembly should be replaced e 208 elements are used for ovens with a 208V supply 240 volt elements are used for ovens with 220V 230V or 240V supply 380 elements are used for ovens with a 380V supply 480V elements are used for ovens with a 416V or 480V supply All heaters are connected in Delta Heaters are grouped into four assemblies
264. t all of the rear wall thermocouples are con nected to the terminal block inside the left blower mo tor compartment It is not necessary to access the right blower motor compartment Remove the screws that hold the thermocouple to the wall Slide the thermocouple out of its mounting hole Disconnect the thermocouple leads Rear wall ther mocouples are connected to the terminal block inside the left blower motor compartment High limit thermo couples are connected directly to the high limit control module Remove and discard the thermocouple Install the new thermocouple into its mounting hole Fasten it in place with the supplied 6 x 3 8 screws Wire the thermocouple as shown in Figure 10 If you replaced a rear wall thermocouple use the kit supplied nylon clamp and 10 16 x 3 4 screw to se cure the thermocouple leads so that they will clear the shrouds blower belts and pulleys Replace all shrouds onto the oven Close the machin ery compartment door Thermocouple Wiring PS555 Electric and PS555E Temperature sensing thermocouple leads Ground Red White leads Left Y 2 Block To temperature To ground controller terminal on temp controller Temperature sensing thermocouple leads Red White Shielded ground lead dE TC TC RESET L2 L1 OQ High Limit Control NO NC Module a
265. t attaches the thermocouple mounting tube as per the replacement procedure above For these ovens simply disconnect the thermocouple wiring from the temperature controller and follow Steps 3 6 of the procedure shown above to remove and replace the thermocouple On some of these ovens the thermocouple flange rests ON TOP of the retaining screw for the mounting tube as shown in the INCORRECT inset of Figure 1 These ther mocouples are held in place by the set screw on the mount ing tube inside the plenum chamber For these ovens you should remove and replace the thermocouple by following Steps 1 6 of the preceding section Figure 1 Thermocouple Installation PS200 Series Mounting Mounting tube tube screw Thermocouple flange Thermocouple Set screw not used with new Tube thermocouple flange CORRECT Thermocouple flange sits firmly on mounting tube flange tube mounting screw holds thermo couple in place INCORRECT Thermocouple flange sits on top of screw head leaving a gap as shown Figure 2 Thermocouple Wiring PS200 Series White 9 Red 6 Digital Temperature Controller 4 13 Shielded ia 15 ground 16 Shielded ground lead
266. t injury caused from hidden gas leaks which could cause tlashback in the machinery compartment Light the main burner 4 With the burner in operation paint all pipe joints and gas contro inlet and oullet with rich and water solulion 5 if another gas leak is detected tighten joints and pipe connactions 6 Replace the part if gas leak cannot be stopped ADJUST THE PILOT BURNER FLAME The pilot llame should envalop 3 8 to 1 2 inch 10 to 13 millimaters of the ignitor sensor tip A MILCIMETRES Reter to Figure 3 To adjust the pilot flame 1 Remove the pilot adjustmant cover screw Rafer to Figure 1 ADJUSTMENT 2 Turn the inner adjustment screw clock IQNITER SKNSOR wise to decrease or countarclockwise to In crease the pilot flame 3 Always replace the cover screw after ad justment and tighten firmly to ensure proper operation Figure 3 Proper Flame Adjustment Shut off the gas eupply at the service valve behind the oven before removing the oullel pressure tap plug or betore disconnecting tho manometer ADJUST MANIFOLD PRESSURE 1 The gas control outlet pressure should be 3 5 w c for natural gas and 10 6 w c for propane gas 2 Wilh the main burner operating check the gas pressure using a manometar connected to the gas control outlet pressure tap Refer to Figure 1 3 if necessary adjust the pressure regulator a Remove the pressure regulator adjustment cap b Using screwdri
267. temperatures Check that all manual gas cocks are open supply tubing and pressures are good and pilot burner orifice is not blocked eCheck electrical connections between control board and pilot operator on gas control eCheck for Vac fused control board or 25 Vac non fused control board Turn gas supply on Pilot burner lights YES across PV MV PV terminals on control board if voltage is okay replace gas control If no voltage replace control board Spark stops when NOTE If control board goes into lockout reset system pilot is lit YES Check continuity of ignition cable and ground wire Check that pilot flame covers electrode f checks are okay replace control board Check for 12 Vac fused control board or 25 Vac non fused control board across MV MV PV terminals if no voltage replace control board Check electrical connections between control board and gas control If okay replace gas control or gas control operator Main Burner lights 15 YES System runs until NOTE If control board goes into lockout reset system call for heat ends YES Check continuity of ignition cable and ground wire NOTE If ground is poor or erratic shutdowns may occur occasionally even though operation is normal at the time of checkout elf checks are okay replace control board Call for heat ends Replace gas control System shuts off YES Troubleshooting en
268. the door is open grasp the switch actuator and pull it out as far as possible This will close the door switch and permit troubleshooting Closing the control cabinet door will reset the switch Closing the door switch permits a circuit to go through a fuse or circuit breaker as appropriate for the oven model to one side of the conveyor switch blower mo tor switch and to the heat switch Conveyor Switch Closing the conveyor switch permits a circuit to go to the Conveyor Speed Control Module which 1 Sends power to the gear motor conveyor drive mo tor The 120VAC signal to the Conveyor Speed Control Module is rectified to a 90VDC signal which is then sent to the gear motor 2 Allows regulation of conveyor speed Adjusting the thumbwheel or digital pushbutton display unit as appropriate to the desired conveyor belt speed in structs the Conveyor Speed Control Module to regu late the output to the gear motor This increases or decreases the conveyor speed as necessary to match the speed setting shown on the thumbwheel or display unit Blower Switch Closing the blower switch energizes 1 The cooling axial fan s 2 The blower motor contactor s Closing this contactor starts the blower motor s When both blower motors are up to speed centrifugal switch es located inside the rear end of the motor s or air flow switch es as appropriate for the oven model will close setting up the heat circuit 3 The T
269. the oven in the following manner to determine whether the oven has a pressure sensing problem Threaded Pressure 1 Using the normal oven startup procedure BLOWER Setting switch turned ON HEAT switch tumed ON adjust Adjustment the temperature setpoint value on the Temperature Figure 1 Controller to 600 F 315 C If the oven shuts down Alternate Air Pressure before reaching 6009 31590 remove the clear Switch showing pres gt Orange plastic cover of the Air Pressure Switch by loosen sure adjustment device Ll ing the two Phillips head screws attaching it CAUTION Excessive or rapid turning of the Threaded Pressure Setting Adjustment may damage the switch or cause it to lose its calibration ALWAYS adjust the Threaded Pressure Setting Adjustment very slowly and carefully Do NOT turn the Threaded Pressure Setting Adjustment so that it is more than 1 16 1 5mm above or below the rim of its threaded housing Adjust the Threaded Pressure Setting Adjustment Figure 1 slowly counterclockwise in the direction of the arrow pointing to the symbol to keep the burner heater operating until it reaches the 600 F 315 C temperature set point 2 Upon completing this adjustment process reinstall the clear plastic cover to the Alternate Air Pressure Switch NOTE Instructions for replacing an inoperative Alternate Air Pressure Switch with a blue dial Air Switch appear on sheet 2 SECTION 3 SERVICING COMPONENTS
270. then activate the heating elements The relays operate on a fixed cycle time Within each cycle the relays activate the heating elements at 100 for a length of time that is proportional to the signal from the amplifier board When the oven is switched on heat demand is at its peak and the elements are activated for 100 of each cycle As the oven s temperature approaches the set point the relays reduce the length of time that the heat ers are activated wihin each cycle After the oven is fully preheated the heaters are usually activated for about 30 of each cycle This system allows the ac tual oven temperature can remain constant with NO temperature swing IMPORTANT The PS555 electric oven uses a variable pulse system that is designed to emu late the PID gas operating mode Because of this the temperature controller MUST be set to the PID operating mode Temperature controller P N 46837 inc with Service Kit 47321 includes a dedicated vari able pulse mode intended for the PS536 elec tric oven This mode is NOT used on the PS555 electric oven If you are using controller P N 46837 be sure to set the controller for the PID operating mode Refer to Temperature Controller on Page 30 Heaters are arranged into four assemblies each of which contains three elements Each pair of assem blies left and right share a controller and a 50A circuit breaker block NOTE All control wire used on this oven is AWM rated a
271. tmaster Drive Elgin IL 60120 847 741 3300 FAX 847 741 4406 Marshall Oven Gas Conversion Kit p n 36863 PS360EWB and PS360WB70 Propane to Natural Gas Installation Instructions WARNING This conversion kit is to be installed by Middleby Marshall Authorized Service Organization accordance with the manufacturer s instructions and all codes and requirements of the authority having jurisdiction Failure to follow instructions could result in serious injury or property damage The authorized service organization performing this work assumes responsibility for this conversion This kit consists of the following parts Qty Units Description ea 36862 Instructions for Conversion of Propane Operation to Natural Gas Operation PS360EWB and PS360WB70 ea 31818 Orifice Pilot Assembly Natural Gas 0 032 0 81mm ea 31821 Orifice Main Natural Gas 0 234 5 94mm ea 22174 0006 Orifice Low Flame Nat Gas 0 065 1 65mm 53 drill used for converting PS360WB70 only ea 22500 0064 Label NAT Green ea 22500 0123 Label Conversion Gas IMPORTANT AN When converting any oven that is installed at an altitude above 5000 ft 1524m consult Middleby before installing this Kit 1 PREPARATION 1 1 Turn off the electric power supply to the oven 1 2 Turn off the gas supply at the service valve behind the oven WARNING peitorming any service or conversion work the electrical power supply A
272. turi mounting plate to the front of the burner Remove the gas train venturi assembly from the oven COMBINATION GAS CONTROL VALVE SAFETY REGULATOR CONVERSION Remove and discard the following components from the combination gas control valve as shown in Figure 2 e Regulator cap screw e Regulator adjustment screw e Regulator spring Install the red kit supplied regulator spring with the tapered end facing into the valve as shown in Figure 2 Install the white kit supplied regulator adjustment screw Carefully adjust the screw until its top is flush with the top of the regulator Turn the adjustment screw six complete turns in a clockwise direction This preliminary pressure setting is approximately 10 1 2 W C 26 1mbar Install the black kit supplied cap screw BYPASS ORIFICE CONVERSION NOTE Ovens are equipped with EITHER an on offsolenoid valve with a separate bypass line OR with a modulating gas valve Refer to the illustrations on Page 2 When installing this Kit the bypass orifice will only be changed if the oven is equipped with a solenoid valve Ifthe oven is equipped with a modulating gas valve skip ahead to Section IV Pilot Orifice Conversion Ifthe oven is equipped with a solenoid valve continue on to Step 1 below Unscrew the compression nuts at both ends of the bypass tube and slide them back and out of the way Then remove and retain the tubing See Figure 3 Remove and discard the existing
273. ugs and connections are rated at 600 F 316 C All heating elements are double nutted The rear of each heating element is held to other elements by a spacer bracket The only way the element can be changed is by removing the entire bank from the oven To remove the element bank 1 Remove the 4 bolts holding the bank of element to the oven See Figure 80 2 Remove the 9 electrical leads going to the element bank See Figure 81 3 Gently workthe bank of elements out of the oven Be careful to pinch the wires between the frame of the oven and the side plate of the heating ele ments See Figure 82 4 Remove the bank of elements and place them on the floor The entire bank may now be serviced 5 Removethe element jumper wires and element cover if individual elements need replacement NOTE The spacer brackets MUST be reinstalled be fore assembling the element bank back into the oven These brackets keep the elements from touching each other during use See Figure 82 SECTION 3 SERVICING COMPONENTS C PS555 ovens 1 Description of heating system All PS555 electric ovens use a variable pulse system for heater activation In response to the millivolt signal from the thermocouple the temperature controller sends a 4 20mA signal to a controller module This module contains an amplifer board and two solid state relays The amplifier board receives the 4 20mA signal and in turn activates the relays The relays
274. uple source to verify correct operation Using the read function of the temperature controller verify and record the high ambient reading Verify positive ignition on cold start 172 SECTION 5 REFERENCE Fractional inches to decimal and millimeter equivalents INCH DECIMAL METRIC FRACTION EQUIVALENT EQUIVALENT 015625 03125 046875 0625 078125 09375 109375 125 140625 15625 171875 1875 203125 21875 234375 25 265625 28125 296875 3125 328125 34375 359375 375 390525 40625 421875 4375 453125 46875 484375 5 INCH DECIMAL METRIC FRACTION EQUIVALENT EQUIVALENT 5 15625 53125 546875 5625 578125 59375 609375 625 640625 65625 671875 6875 703125 71875 734375 75 765625 78125 796875 8125 828125 84375 859375 875 890625 90625 921875 9375 953125 96875 984375 1 000 Decimal equivalents of drill sizes DRILL DRILL ORILL DRILL SIZE DIAMETER SIZE nok WN DIAMETER SIZE DIAMETER SIZE DIAMETER dimensions are given in inches See decimal equivalents Drills designated in fractions are available in diameters 1 8 to 4 in increments of 1 64 173 13 097 13 494 13 891 14 287 14 684 15 081 15 478 15 875 16 272 16 669 17 067 17 463 17 860 18 238 18 635 19 049 19 446 19 842 20 239 20 636 21 033 21 430 21 827 22 224 22 621 23 018 23 415 23 812 24 208 24
275. using 1 2 hex nuts an 11 16 wrench See Figure 4 Install the kit supplied main orifice into the holder REASSEMBLY Check that the pilot assembly is correctly aligned with the venturi as shown in Figure 5 If necessary reposition the pilot assembly Reassemble the venturi and mounting plate to the gas train assembly Replace the two 1 2 hex nuts to hold the assembly together Replace the assembled gas train into the oven Tighten the gas pipe union on the inlet side of the combination gas valve to hold the gas train in place Figure 5 View from side of venturi View from rear of venturi Rear edge of pilot hood is on centerline of venturi Pilot hood 3 8 9 5mm 11 16 17 5mm 128 SECTION 3 SERVICING COMPONENTS Appendix Instructions for All Gas Conversion Kits for Ovens with Wayne Burner Propane to Natural Gas 8 00 VII GAS LEAK TEST 1 Restore the electrical and gas utility connections to the oven Paint all gas pipe connections from the union to the venturi mounting plate as well as the pilot tubing bypass tubing and pressure tap plug with a rich solution of soap and water 2 3 soap 1 3 water is recommended Any visible bubbles indicate a gas leak If a gas leak is detected tighten the affected joints and connections Iftightening the connection s fails to stop the leak Turn off the electric power supply to the oven Turn off the gas supply service valve
276. ve the wireway cover Figure 83 SECTION 3 SERVICING COMPONENTS Disconnect the electrical lead connections from the front of the oven to the remote terminal blocks on the back wall Then disconnect the leads from the remote terminal blocks to the elements Remove the 8 hex bolts that hold the rear wall panel to the body of the oven Once removed DO NOT lay the panel on either its front or back side This can damage the heating elements blower fan and bearings The panel should be kept upright Remove the two hex head screws that hold the element assembly to the back wall When replacing the rear oven panel be sure to use a high temperature never seize lubricant on the 8 hex bolts that hold the panel in place 5555 electric oven heating element removal Lock Remote washer terminal blocks pex X 2 07 qo Hex head screw ii Wireway cover 145 Hex head screw Flat Heating Washer element assembly SECTION 3 SERVICING COMPONENTS D Mercury Contactor Replacement Early PS200 series electric ovens and all PS310 360 se ries electric ovens use mercury contactors to activate the heating elements Each pole in the contactor is a separate mercury filled tube that is individually replaceable This feature ensures that the entire contactor should never have to be replaced Individual part numbers for the mercury contactor compo nents are listed in the Part Number
277. ver turn the inner adjustment screw clockwise to increase or counterclock wise to decrease tho main burner gas pressure c Always replace the cap screw and tighten firmly to ensuro proper oparalion 4 I the desired outlet gas pressura cannot be achieved by adjusting the gas control check the gas control inlet pressure using a manomater at the inlet pressure tap If the inlet prossure is atleast 6 w c 11 w c for propane replace tho gas control Otherwise the necessary steps to provide proper gas pressure to the gas conuol 5 Be sure the main burnar primary air supply is properly adjusted for completa combustion approximately 1 4 to 3 B open 8 Perlorm gas leak test at the pressure tap plugs SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 42810 0121 Combination Gas Valve 1 92 Middleby Marshall Marshall Inc 8300 Austin Ave Morton Grove IL 60053 706 908 8300 TWX910 223 0211 FAX 706 966 8701 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kit 42810 0114 Ignition Module 11 90 INSTALLATION INFORMATION P N 88210 0058 NEW HONEYWELL IGNITION MODULE P N 27161 0005 OLD HONEYWELL IGNITION MODULE P N 27161 0004 REPLACING OLD MODULE WITH NEW WHEN REPLACING AN OLD MODULE WITH A NEW MODULE IT IS MANDATORY TO REMOVE AND DISCARD THE BURNER TRANSFORMER GROUND WIRE SEE FIGURE 1 This groun
278. way from the switch permitting the contacts to close This com pletes the heat circuit allowingthe burner to light If the burner blower motor is not operating the switch will not close and the circuit remains open preventing burner activation No adjustment can be made to the switch If it is not oper ating properly the burner blower motor must be replaced Figure 49 PS360 series blower motor centrifugal safety switch Switch 80 AIRPRESSURE SAFETY SWITCH PS200 SERIES PS555 570 SERIES PS360EWB PS360WB70 Middleby ovens have a safety feature that prevents the burner heating elements from activating if the blower s are not in operation On PS200 series ovens and PS555 570 series ovens this feature is controlled by a separate air pressure switch that reads air flow from the blower One switch is used for each blower 1 for the PS200 series 2 for the PS555 570 series These ovens cannot use a Centrifugal switch on the motor because they use an indirect belted drive system If a belt fails it is possible for the motor to operate normally while the blower itself is stopped In addition gas ovens with a line voltage burner blower mo tor use an identical air switch to check that the burner blower motor is operating before burner activation These ovens include the PS360EWB PS360WB70 PS555 PS555G and PS570G as well as PS200 series ovens equipped with the modulating gas system This additional air switch i
279. wer Plenum Burner blower motor Pilot line SECTION 3 SERVICING COMPONENTS D Pilot Ignitor Assembly Figure 63 Pilot ignitor assembly The pilot assembly is attached to the end of the pilot line Pilot line It consists of an ignitor electrode flame sensor a pilot shield connects here and the pilot burner See Figure 63 visis urner The pilot assembly includes a safety circuit An electrical current is sent to the flame sensor probe to prove the pres Hood ence ofthe pilot flame When the spark ignites the pilot a circuit is completed THROUGH THE FLAME from the flame sensor probe to the pilot burner which is grounded This safety circuit must be completed before the pilot will light 1 Pilot Shield The pilot shield is a plate located on the bottom of the pilot It prevents drafts etc from blowing the pilot flame Ignitor sensor Spark cable away from the sensing probe See Figure 64 prabe connects Nere 2 Flame target The flame target aids in distributing the flame from the end of the venturi See Figure 65 Figure 64 PS310 360 series ovens built prior to 6 87 are not End of burner without flame target equipped with a flame target The burner on these ovens resembles the one shownin Figure 64 showing pilot shield angled flame target is used on PS200 series ovens built through 3 02 PS310 PS314 PS360 PS360WB ovens built 6 87 or later PS5
280. ws the burner to operate in low flame mode while awaiting re activation When the oven has been fully preheated and has main tained the set point for about an hour with a moderate prod uct load the low flame to high flame ratio should be ap proximately 1 to 1 That is the oven will be calling for heat approximately half the time To check this ratio refer to the HEAT indicator on the temperature controller which will only be active when the burner is on high flame EXCEPTION Older PS310 314 360 ovens have ture sensing thermocouple mounted at the front of the oven inside the machinery compartment On these ovens the low flame to high flame ratio should be approximately 2 or 3 to 1 oven calls for heat 1 3 or 1 4 of the time IMPORTANT For proper functioning of the sole noid valve the temperature controller MUST be set to the on off operating mode Refer to Tem perature Controller on Page 31 J Bypass Low Flame Orifice ovens with a high flame solenoid valve only All ovens that use an on off gas regulation system are equipped with an orifice in the low flame bypass line See Figure 70 When the oven is not calling for heat the solenoid valve is closed but gas is still supplied to the burner through the bypass line This allows the burner to operate in low flame mode while awaiting re activation The low flame orifice regulates the gas flow through the bypass line If the orifice size is too l
281. y remaining sili cone can interfere with the correct placement of the new thermocouple 5 6 Analog N sls Insert the new thermocouple until its flange is seated Temperature 1 G on the end of the mounting tube See Figure 5 Controller Tighten the set screw until the thermocouple is secure inside the tube AVOID OVERTIGHTENING THE SET GI GIG GIG GO SCREW TO PREVENT DAMAGE TO THE THERMO 3 10 11 12 13 14 15 16 COUPLE Red White Use high temperature silicone to seal the flange to the E Shielded mounting tube as shown in Figure 5 Check that all ground lead 2 holes and spaces are filled by the silicone This not High Limit only helps to hold the thermocouple in place but pre Control vents heat from entering the machinery compartment Module Route the wiring for the new thermocouple through the hole in the side of the electrical control box by using the existing wiring bundle Check that the leads are clear of the ignition cable and all components Connect the leads as shown in Figure 6 SECTION 3 SERVICING COMPONENTS Appendix Instructions for Service Kits 33984 and 33985 Oven Thermocouple Kit 11 01 PS536 Thermocouples on these ovens are located inside the ma chinery com
282. ystems Group 1400 Toastmaster Drive m Elgin 5 60120 708 741 3300 m Service amp Parts 708 741 4406 YZ Middleby 7728 Marshall Service Bulletin Subject instaliation and Diagnostic instructions DIP Switch Conveyor Control Assembly Part Number 42810 0133 Application This service bulletin describes the original DIP switch conveyor control Part Number 28074 0018 the new DIP switch conveyor speed control Part Number 31020 and introduces the latest instructions for installation and set up Either control can be contained in Kit Part Number 42810 0133 Both controls use advanced digital electronics to improve reliability and provide diagnostic features The installation and operation of these controls are identical to each ether and both replace prior non DIP switch model controls Both control s printed circuit boards are housed in metal covers and both have detachable replaceable and interchangeabie thumbwheel switches The distinguishing features between the and the current control are the DIP switch blocks and the markings on their metal covers Controi PN 28074 0018 has a 4 position DIP switch and the contro PN 31020 has an 8 position DIP switch Control PN 31020 has its individua DIP switch program settings silk screened on the metal cover for easy reference Features 1 Conirol Number 31020 has enhanced tolerance to electrical systems that have unstable frequency contro 50 or 60 cycles

Middleby Marshall Oven PS360 User's Manual

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