Middleby Marshall PS540 (Double) Operating And Installation Manual
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Middleby Marshall PS540 (Double) Operating And Installation Manual

Middble by marshall electric oven owner's operating & installation manual
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Middleby
Middleby
Middleby
Middleby
Middleby
Marshall
Marshall
Marshall
Marshall
Marshall
A MIDDLEBY COMPANY
owner's
operating
& installation
manual
PS540-Series OVENS
Model PS540E
PS540 (Double)
©2006 Middleby Marshall
®
Inc.
PS540-Series Electric Ovens: English
PS540 (Single)
PS540 (Triple)
Part No. 51415
Price $30.00
P: 10/06

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Summary of Contents for Middleby Marshall PS540 (Double)

  • Page 1 Middleby Marshall Marshall Marshall Marshall Marshall A MIDDLEBY COMPANY owner's operating & installation manual PS540-Series OVENS Model PS540E PS540 (Double) Inc. ©2006 Middleby Marshall ® PS540-Series Electric Ovens: English PS540 (Single) PS540 (Triple) Part No. 51415 Price $30.00 P: 10/06...
  • Page 2 Contact your authorized Service Agency to perform maintenance and repairs. A Service Agency Directory is supplied with your oven. Using any parts other than genuine Middleby Marshall factory-manufactured parts relieves the manufacturer of all warranty and liability. Middleby Marshall (Manufacturer) reserves the right to change specifications at any time.
  • Page 3 © 2003 - Middleby Marshall, A Middleby Company. The Middleby Marshall logo is a registered trademark of Middleby Marshall, A Middleby Company. Middleby Marshall Inc. • 1400 Toastmaster Drive • Elgin, Illinois 60120-9272 U.S.A. • (847) 741-3300 • FAX: (847) 741 4406 Serial No.

  • Page 4: Table Of Contents

    Wiring Diagram, E380-480 50/60, 3PH 5W PS540 ... 64 Wiring Diagram, E380V 50/60, 3PH 5W PS540 ... 65 Wiring Diagrams are in Section 7 of this Manual. The diagram for each oven is also on the lower inner surface of its Control Console. (Continued)

  • Page 5: Model Identification

    SECTION 1 DESCRIPTION I. MODEL IDENTIFICATION The Middleby Marshall PS540-Series may be used either as a single oven or stacked for use as double or triple ovens. The major difference between the oven models in this series is the width of the conveyor.

  • Page 6: Series Ps540 Electrical Specifications

    208-240V 400V 208-240V Wiring Diagrams are contained in Section 7 of this Manual and are also located inside the oven at the This Manual Must Be Kept For Future Reference 32″ (813mm) 40-1/2″ (1028mm) 9 sq. ft. (0.84 sq. m.) 80″...

  • Page 7: Principle Of Air Flow

    II. PRINCIPLE OF AIR FLOW The fan-style blower draws air into the oven plenum where it is heated. The blower then pushes the hot air through the air fingers into the baking chamber. Each air finger contains an inner plate and outer plate that form the hot air into jets, distributing it across a conveyor belt on which the food product rides.

  • Page 8: Principle Of Air Flow (Continued)

    A PS540-Series Oven can accommodate up to four bottom air fingers and four top air fingers. Some PS540- Manifold...

  • Page 9: Component Function

    SECTION 1 DESCRIPTION III. COMPONENT FUNCTION (Figure 1-6) Figure 1-6. PS540-Series Oven Components Locations...

  • Page 10: E. Cooling Fan

    B. Blower Fan The blower fan is located at the rear of the oven. This blower forces heated air through the air fingers. The BLOWER switch must be set to “ON” or “I” for oven warmup and baking.

  • Page 11: Cooling Fan

    SECTION 1 DESCRIPTION Figure 1-8. Cooling Fan...
  • Page 12 SECTION 1 DESCRIPTION Half Blank Plate Outer Plate Inner Plate Blank Plate Finger Manifold Assembly Figure 1-9. Blank Plates (two sizes) and an Air Finger. F2. Blank Plates 1. Blank Plates- The Blank Plates are available to install on the plenum where an air finger is not required. Baffle...

  • Page 13: Section 2 I. Unloading

    SECTION 2 INSTALLATION I. UNLOADING Your Middleby Marshall PS540-Series Oven is shipped partially assembled. It will arrive in a carton on a crate. Carton size for a PS540-Series Oven is: 84″ (2134mm) Long ×...

  • Page 14: Type Of Installation

    Gas Oven INSTALLATION Installation Kit P/N 50663 PS540 Single Oven PS540 Double Oven PS540 Triple Oven PARTS LIST FOR SERIES PS540 GAS OVEN ITEM PS540 OVEN INSTALLATION REQUIRED KITS AND EQUIPMENT PS540 Single PS540 Double Oven Option Oven Option Base w/15″ Legs, Base w/6″...

  • Page 15: Parts List For Ps540 Series Single Oven Option - Base W/15" " " " " Legs & Top P/N 34832

    Figure 2-2. Model PS540 Single Oven Option Base with Legs and Top PARTS LIST FOR PS540 SERIES SINGLE OVEN OPTION - BASE w/15″ ″ ″ ″ ″ LEGS & TOP ITEM PART NO. 37900-0025 37900-0024 22290-0009 22290-0010 220373 21416-0001 21422-0001...

  • Page 16: Section 2 Installation

    SECTION 2 INSTALLATION PARTS LIST FOR PS540 SERIES DOUBLE OVEN OPTION - BASE w/6″ ″ ″ ″ ″ LEGS, CASTERS & TOP ITEM Figure 2-3. Model PS540 Double Oven Option Base with Legs and Top P/N 34833 PART NO. DESCRIPTION...

  • Page 17: Option - Base W/Outriggers & Top

    Figure 2-4. Model PS540 Triple Oven Option Base with Outriggers and Top PARTS LIST FOR PS540 SERIES TRIPLE OVEN OPTION - BASE w/CASTERS & TOP ITEM PART NO. 54606 45209 22290-0009 22290-0010 45206 45205 220373 21416-0001 21422-0001 21172-0004 21216-0018 21416-0003...
  • Page 18 INSTALLATION Figure 2-5. MODEL PS540 SINGLE OVEN DIMENSIONS GAS INLET ELECTRICAL JUNCTION BOX RECOMMENDED MINIMUM CLEARANCES: Rear of Oven to Wall - 6″ (150mm) Non-control End of Oven to Wall - 0″ Control End of Oven to Wall - 0″...
  • Page 19 INSTALLATION Figure 2-6. MODEL PS540 DOUBLE OVEN DIMENSIONS GAS INLET ELECTRICAL JUNCTION BOX RECOMMENDED MINIMUM CLEARANCES: Rear of Oven to Wall - 6″ (150mm) Non-control End of Oven to Wall - 0″ Control End of Oven to Wall - 0″...

  • Page 20: Restraint Cable Installation

    SECTION 2 INSTALLATION Figure 2-7. MODEL TRIPLE OVEN DIMENSIONS RESTRAINT CABLE INSTALLATION Install the restraint cable assembly on the oven, as shown in Figure 2-6. Figure 2-8. Restraint Cable Assembly Installation GAS INLET ELECTRICAL JUNCTION BOX RECOMMENDED MINIMUM CLEARANCES: Rear of Oven to Wall - 6″ (150mm) Non-control End of Oven to Wall - 0″...

  • Page 21: Utility Rough-In Dimensions And Positioning For Ps540-Series Ovens

    ELECTRICAL SPECIFICATIONS DOMESTIC or EXPORT: 208-240V blower motor, 1 phase, 4.1 Amp draw, 50/60 Hz, 208-240V control circuit, 2 poles, 3-wire system per oven (2 hot, 1 grd). Do NOT use conduit for ground. GAS RATING Model PS540 is 110,000 BTU/hour (27,720 kcal), 32.2 kW/hr.

  • Page 22: Ventilation Guidelines

    SECTION 2 INSTALLATION II. VENTILATION GUIDELINES A mechanically driven ventilation system is required for the PS540 Series Middleby Marshall conveyorized elec- tric ovens. The minimum hood canopy dimensions are outlined below. Local codes and conditions vary greatly from one area to another and must be complied with.

  • Page 23: Electrical Connection Information For Ps540-Series Ovens

    (Refer to the wiring diagrams of Section 7.) All gas oven electric supply connections are made via the electrical junction box on the rear of the oven (Figure 2-12). The power lines then connect through an oven safety switch (on the control console door frame) to the oven circuits.

  • Page 24: Conveyor Rear Stop And End Stop Installation

    STOP INSTALLATION Locate the conveyor rear stop and end stop in the installation kit. Install the rear stop and end stop at the exit end of the oven. See Figure 2-13. Conveyor End Stop Figure 2-13. Installing Rear and End Stops...

  • Page 25: Control Functions

    A possibility of injury from rotating parts and electric shock exists in this oven. Never disassemble or clean the oven with the BLOWER switch or any other oven control turned “ON” or “I”. Turn “OFF” or “O” and lockout or tagout all electric power to the oven before attempting to clean or service this oven.

  • Page 26: Component Information And Location

    B. Blower Switch The blower switch has two positions. The switch must be “ON” or “I” for the burner to come on and permit the oven to warm up. The fan circulates the air throughout the oven and must stay on during baking and during the cool down cycle above 200°F (93°C) to prevent blower bearing...

  • Page 27: Conveyor

    This should be the conveyor speed shown on the conveyor speed digital control. NOTE: In Figures 3-4 and 3-5, the oven shown is with the conveyor running right to left. WARNING Possibility of injury from rotating parts and electrical shock exist in this oven.

  • Page 28: Step-By-Step Operation

    Air is exhausted through the front of the cabinet and also out the front of the oven. Refer to Daily Maintenance Section for fan intake checking procedure.
  • Page 29 SECTION 3 OPERATION 4. Open the oven window. Figure 3-6. Control Panel...

  • Page 30: Normal Operation - Step-By-Step

    This al- lows you to monitor the oven temperature as it rises to the setpoint. Allow the oven to preheat for 10 minutes after it has reached the set point temperature. DAILY SHUTDOWN PROCEDURE Turn the "HEAT" ( ) and "BLOWER"...
  • Page 31 Lights when the set point is locked out from changes. This setting can only be changed by service personnel. OVERTEMP Light Lights when the oven temperature is greater than 650°F (343°C). Refer to Quick Reference: Troubleshooting in this section. Temperature...

  • Page 32: Quick Reference: Troubleshooting

    Controls may be set incor- overcooked or rectly. undercooked. IF THESE STEPS FAIL TO RESOLVE THE PROBLEM, CONTACT YOUR LOCAL MIDDLEBY MARSHALL AUTHORIZED SERVICE AGENT. A SERVICE AGENCY DIRECTORY IS SUPPLIED WITH YOUR OVEN. PROBLEM • Follow the procedures under Daily Shutdown Procedures in this section to shut down the oven.

  • Page 33: Section 4 Maintenance

    If the oven is to be removed from its installed location for servicing, perform the following procedure: 1. Switch off the oven and allow it to cool. Do NOT service the oven while it is warm. 2. Turn off main circuit breakers and disconnect connector from oven.

  • Page 34: Maintenance - Daily

    D. Crumb Pans (Figure 4-2) Remove and clean the crumb pan at each end of the oven. Each crumb pan can be removed by sliding it out, as shown in Figure 4-2. Reinstall the crumb pans after cleaning.

  • Page 35: Maintenance - Monthly

    For heavier cleaning of baked on grease and carbon deposits use a non-caustic cleaner that will not react with the aluminized finger manifold surfaces. You can order non-caustic cleaner from your local autho- rized Middleby Marshall Parts Distributor in the quantities listed below: Part # 27170-0244...
  • Page 36 Figure 4-7. 7. Continue sliding the conveyor completely out of the oven, fold it in half and then place it to the side for cleaning. Be careful not to bump drive sprocket while handling conveyor or damage may result to drive shaft.

  • Page 37: Air Fingers Disassembly For Cleaning

    Fingers are marked in the order shown; as viewed from the front of the oven. (The marks for an upper oven should be preceded with a “U”, example UB1, UT2, etc.) Standard Fingers 2.

  • Page 38: Cleaning The Window

    Figure 4-15. 2. Push the window all the way inside the oven, making sure it is clear of the frame. Now, turn the window sideways while inside the oven and then remove it. This will avoid breaking the window.
  • Page 39 2. Reassemble the inner plate. Keep your fingers clear so you won’t pinch them. The inner plate of a finger will only go in one way because of its design. 3. Replace the outer plate by placing your hands flat on the top of the plate and pushing down.
  • Page 40 SECTION 4 MAINTENANCE 5. Install fingers and blank plates correctly with edges interlocked and no space between edges. Top Finger Tab on Outer Plate of Finger Located in Groove Top Finger Tab on Outer Plate of Finger Located in Groove Top Finger Tab on Outer Plate of Finger Located in Groove...

  • Page 41: Reinstall End Plugs

    SECTION 4 MAINTENANCE E. Reinstall End Plugs 1. Reinstall lower end plug. Be sure to tighten two wing screws on the end plug. 2. Reinstall conveyor. 3. Reinstall upper end plug. Be sure to tighten two wing screws on the end plug. Figure 4-22.

  • Page 42: Conveyor Reassembly Into Oven

    1. Lift conveyor and position it in oven as shown. NOTE: Conveyor assembly may be inserted into either end of oven. If it is to be installed from the non-drive end of the oven the drive sprocket assembly must be removed as shown in conveyor disassembly section.

  • Page 43: Conveyor Belt Link Removal

    H. Conveyor Belt Link Removal 1. Using long nose pliers, an entire link can be removed with the conveyor assembly either in or out of the oven. Position master links at end of conveyor as shown in Figure 4-27. Master Links Figure 4-27.

  • Page 44: Replacing Conveyor Belt

    The section of the conveyor belt furnished with the oven in the installation kit may then be used to replace a section. Follow the preceding procedure “H. Conveyor belt link removal”...

  • Page 45: Maintenance - Every 3 Months

    Shut OFF gas supply to oven. NOTE: It is recommended that the 3-month mainte- nance be performed by an authorized Middleby Marshall technician. Cleaning the Blower/Fan Motor To gain access to the blower/fan motor, open the control cabinet door by removing the three screws.

  • Page 46: Electrical Terminals

    Figure 4-39. Figure 4-39. C. Ventilation Check that the air circulation throughout the oven is not blocked and is working properly. D. Checking the Blower/Fan Belt 1. Check the main blower/fan belt for proper tension and wear.

  • Page 47: Blower Fan Shaft Bearing Lubrication

    Wipe off any excess grease on and around the bearing. Reinstall the rear shroud to allow the oven to operate Grease the two (2) main blower fan shaft bearings (Figure 4-43), using a special grease (MM P/N 17110-0015 lithium- base, high-temperature grease).
  • Page 48 SECTION 4 MAINTENANCE 6. Make sure bronze washer is in between the two halves. Figure 4-47. 7. Place the idler shaft assembly back into place and reinstall the adjustment screws. Figure 4-48. 8. Loosen the set screw on each conveyor drive sprocket and remove sprockets.

  • Page 49: Maintenance - Every 6 Months

    16. Follow conveyor reassembly instructions in Monthly Maintenance Paragraph “F”. NOTE: It is recommended that the 6 Month Maintenance schedule be performed by a Middleby Marshall authorized service technician. IV. MAINTENANCE - EVERY 6 MONTHS A. Check brushes on D.C. conveyor motor, when worn to less than 1/10″...

  • Page 50: Key Spare Parts Kit

    An oven can be purchased with a Key Spare Parts Kit (Figure 4-56). (The kit can be purchased when the oven is ordered, or later, from a Middleby Marshall Authorized Parts Distributor). The kit contains many of the crucial PS540-SERIES ELECTRIC OVEN KEY SPARE PARTS KIT (Figure 4-56) ITEM PART NO.

  • Page 51: Section 5 Troubleshooting

    OVEN BLOWER AND CONVEYOR OPER- ATE, YET THE OVEN IS NOT HEATING Start the oven again. If the oven still does not heat, call your Middleby Marshall Service Agency. setting. CONVEYOR WILL NOT HOLD PROPER SPEED OR WILL NOT RUN AT ALL Check for proper tension of conveyor drive chain and conveyor belt.
  • Page 52 SECTION 5 TROUBLESHOOTING NOTES...

  • Page 53: Section 6 - Parts List

    SECTION 6 PARTS LIST SECTION 6 - PARTS LIST...
  • Page 54 SECTION 6 PARTS LIST...

  • Page 55: Oven Panels, Window And Legs

    SECTION 6 PARTS LIST...
  • Page 56 SECTION 6 PARTS LIST...

  • Page 57: Control Panel

    SECTION 6 PARTS LIST...
  • Page 58 SECTION 6 PARTS LIST...

  • Page 59: Blower And Shroud

    SECTION 6 PARTS LIST...
  • Page 60 SECTION 6 PARTS LIST...

  • Page 61: Conveyor

    SECTION 6 PARTS LIST...
  • Page 62 SECTION 6 PARTS LIST...

  • Page 63: Split Belt Conveyor

    SECTION 6 PARTS LIST...
  • Page 64 SECTION 6 PARTS LIST...

  • Page 65: Machinery Compartment

    SECTION 6 PARTS LIST...
  • Page 66 SECTION 6 PARTS LIST NOTES...

  • Page 67: Section 7 Electrical Schematics

    SECTION 7 ELECTRICAL SCHEMATICS SECTION 7 ELECTRICAL SCHEMATICS...

  • Page 68: Wiring Diagram, E380-480 50/60, 3Ph 5W Ps540

    SECTION 7 ELECTRICAL SCHEMATICS...

  • Page 69: Wiring Diagram, E380V 50/60, 3Ph 5W Ps540

    SECTION 7 ELECTRICAL SCHEMATICS...
  • Page 70 SECTION 7 ELECTRICAL SCHEMATICS...
  • Page 72 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.

This manual is also suitable for:

Ps540ePs540 series

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