Middleby Marshall PS540 Owner's Operating And Installation Manual
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Middleby Marshall PS540 Owner's Operating And Installation Manual

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A MIDDLEBY COMPANY
owner's
operating
& installation
manual
PS540-Series OVENS
Model PS540G
PS540 (Double)
©2006 Middleby Marshall
®
Inc.
PS540-Series Gas Ovens: English
PS540 (Single)
PS540 (Triple)
Part No. 50664
Price $30.00
P: 10/06

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Summary of Contents for Middleby Marshall PS540

  • Page 1 Middleby Marshall Marshall Marshall Marshall Marshall A MIDDLEBY COMPANY owner's operating & installation manual PS540-Series OVENS Model PS540G PS540 (Double) Inc. ©2006 Middleby Marshall ® PS540-Series Gas Ovens: English PS540 (Single) PS540 (Triple) Part No. 50664 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

    GAS BURNER AND PIPING ASSEMBLY ... 63 MACHINERY COMPARTMENT ... 65 SECTION 7 ELECTRICAL SCHEMATICS Wiring Diagram, G208-240 50/60, 1PH 3W PS540 ... 67 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.

  • Page 5: Model Identification

    The major difference between the oven models in this series is the width of the conveyor. A single PS540-Series Oven (Figure 1-1) is mounted on a base pad with legs and casters. A double oven (Figure 1-2) consists of two, stacked, single ovens. A triple oven (Figure 1-3) consists of three stacked single ovens.

  • Page 6: Series Ps540 Electrical Specifications

    2.75 kPa 11.5″ to 12″ Water Column (28.7 to 29.9 mbar) 0.75″ (19mm) ID full-flow, gas, shutoff valve installed in oven inlet gas line. A separate connection and valve must be provided for each oven. One fan at 2300 RPM 3000 fpm (1524 cm/sec) (Average) 3 min.

  • Page 7: Principle Of Air Flow

    This is the reason that the inside of a Figure 1-4. PS540-Series Oven Air Flow PS540-Series Oven is light in color: To reflect more heat back onto the food product. Convection: This path has to do with moving a volume of air.

  • 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 Air Flow From Plenum...

  • Page 9: Component Function

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

  • Page 10: Conveyor Motor And Conveyor Belt

    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 E. Cooling Fan — See Figure 1-8 The cooling fans are located in the back of the oven. These cooling fans draw air through its grille, blowing it through the blower motor compartment and the control compartment into the oven top and exhausted out the front louvers.

  • Page 12: Air Fingers And Blank Plates - See Figure 1-9

    It must be assembled into the manifold with its holes aligned with the holes of the outer plate. 3. Manifold - The Manifold is the assembly which slides on tracks into the oven plenum. Half Blank Plate Outer Plate...

  • 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

    INSTALLATION Installation Kit P/N 50663 PS540 Single Gas Oven PS540 Double Gas Oven PS540 Triple Gas 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″...

  • 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 SECTION 2 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 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″ SECTION 2...

  • 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

    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, 116.0 mJ/h (27,720 kcal), 32.2 kW/hr. MINIMUM GAS METER RATING 450 ft /hour (12.6m...

  • Page 22: Ventilation Guidelines

    SECTION 2 INSTALLATION II. VENTILATION GUIDELINES A mechanically driven ventilation system is required for the PS540 Series Middleby Marshall conveyorized gas ovens. The minimum hood canopy dimensions are out- lined 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: Gas Supply For Gas Heated Ovens

    Section 2 for a list of the installation standards. In addition, because a PS540-Series oven is equipped with casters for accessi- bility during servicing, the gas line connection shall be made with a connector that complies with the Standard for Connectors for Movable Gas Appliances, ANSI Z21.69 (in...

  • Page 25: Conveyor Rear Stop And End Stop Installation

    BTU consump- tion rate for the oven: 116.0 mJ/h, 110,000 BTU/hour for each PS540 Oven. For double oven installations, the BTU/hour requirement for a single oven is doubled. For triple oven installations, the BTU/hour requirement for a single oven is tripled.
  • Page 26 SECTION 2 INSTALLATION NOTES...

  • Page 27: Control Functions

    I. CONTROL FUNCTIONS Figure 3-1. PS540-Series Oven Control Functions The burner cannot operate and gas cannot flow through the burner without electric power. Do NOT attempt to operate the oven during a power outage. A possibility of injury from rotating parts and electric shock exists in this oven.

  • Page 28: 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 29: 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 The burner will not operate and gas will not flow through the burner without electric power.

  • Page 30: 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 31 SECTION 3 OPERATION Figure 3-6. Control Panel...

  • Page 32: 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 33 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 34: 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 35: 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. Shut off main manual gas valve and disconnect gas connector from oven.

  • Page 36: 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 37: Maintenance - Monthly

    To clean the interior, you have to disassemble some parts of the oven. When cleaning your Series PS540 Oven note the following: PRECAUTIONS- 1. Do not use excessive water or saturation of oven insulation will occur.
  • Page 38 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 39: 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 40: 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 41 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 42 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 43: 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 44: 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 45: 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 46: 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 47: 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 48: 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 49: 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 50 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 51: 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 52: 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 GAS OVEN KEY SPARE PARTS KIT, p/n 36805 (Figure 4-56) ITEM PART NO.

  • Page 53: 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 54 SECTION 5 TROUBLESHOOTING NOTES...

  • Page 55: Section 6 - Parts List

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

  • Page 57: Oven Panels, Window And Legs

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

  • Page 59: Control Panel

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

  • Page 61: Blower And Shroud

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

  • Page 63: Conveyor

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

  • Page 65: Split Belt Conveyor

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

  • Page 67: Gas Burner And Piping Assembly

    SECTION 6 PARTS LIST...
  • Page 68 SECTION 6 PARTS LIST...

  • Page 69: Machinery Compartment

    SECTION 6 PARTS LIST...
  • Page 70 SECTION 6 PARTS LIST NOTES...

  • Page 71: Section 7 Electrical Schematics

    SECTION 7 ELECTRICAL SCHEMATICS SECTION 7 ELECTRICAL SCHEMATICS...
  • Page 72 SECTION 7 ELECTRICAL SCHEMATICS NOTES...
  • Page 73 SECTION 7 ELECTRICAL SCHEMATICS NOTES...
  • Page 74 SECTION 7 ELECTRICAL SCHEMATICS NOTES...
  • Page 76 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:

Ps540gPs540 series

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