Middleby Marshall RED LOBSTER PS200-R68 Series Operating And Installation Manual
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Middleby Marshall RED LOBSTER PS200-R68 Series Operating And Installation Manual

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Middleby
Marshall
A MIDDLEBY COMPANY
Red Lobster
©1995 Middleby Marshall
Inc.
NSF
®
Part No. 31349
Price $15.00
P4/95

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Summary of Contents for Middleby Marshall RED LOBSTER PS200-R68 Series

  • Page 1 Middleby Marshall A MIDDLEBY COMPANY Red Lobster Inc. ©1995 Middleby Marshall ® Part No. 31349 Price $15.00 P4/95...
  • Page 2 Seller be liable for a sum in excess of the purchase price of the item. Seller shall not be liable for any prospective or lost profits of Buyer. Middleby Marshall Inc. • 1400 Toastmaster Drive • Elgin, IL 60120 • (708) 741-3300 • FAX (708) 741-4406 National Service Cooperative 1-800-298-1862...

  • Page 3: For Your Safety

    A SERVICE AGENT DIRECTORY IS SUPPLIED IN YOUR Middleby Marshall (Manufacturer) reserves the right to The equipment warranty is not valid unless the oven is installed, started and demonstrated under the supervision This Manual Must Be Kept For Future Reference...

  • Page 4: Table Of Contents

    B. Air Fingers ... 5 III. COMPONENT FUNCTION ... 7 A. Conveyor ... 7 B. Fan C. Gas Burner(Gas Oven Only) ... 7 D. Electric Heaters (Electric Ovens Only) ... 7 E. Front Window ... 7 F. Cooling Fan ... 7 G.
  • Page 5 B. Cooling Fan ... 35 C. Crumb Pans ... 36 II. MAINTENANCE - WEEKLY ... 36 A. Removing Conveyor From Oven For Cleaning ... 36 B. Oven Interior Disassembly ... 38 C. Window Disassembly For Cleaning ... 39 D. Loading The Soak Bin ... 39 E.
  • Page 6 NOTES...

  • Page 7: Section 1 Description

    The Series PS200-R68 single oven is mounted on a base pad with 6" extension legs and casters. A double oven is stacked and the lower oven is on a base pad with casters. Figure 1-1. Middleby™ Series PS200-R68 Ovens SECTION 1...

  • Page 8: Oven Specification Chart

    68"(1727mm) L x Red Lobster Double Oven 57-3/4"(1467mm) W x 76-3/4"(1949mm) H Weight of Single Oven 925 lbs.(419kg) Shipping Weight of Single Oven 1,100 lbs.(498.3kg) Shipping Cube of Single Oven Approx.132 ft (3.74 m Operating Range of Single Oven 120,000 BTU/HR (30,240 kcal) (35.1 kW/HR)

  • Page 9: Electrical Specifications

    GAS HEATED OVENS Main Blower Control Phase & Elements Circuit Voltage Voltage 208-240V 120V 208V 120V Export Transformer 200V 120V Export Transformer 220-240V 120V Export Transformer ELECTRIC HEATED OVENS Main Blower Control Phase & Elements Circuit Voltage Voltage 208-240V 120V 220-240V 120V Transformer...

  • Page 10: Principle Of Air Flow

    II. PRINCIPLE OF AIR FLOW Air is heated and then pulled through the fan which pushes the air into the oven plenum and delivers heated air into the air fingers. The fingers contain an inner plate and outer plate which columnate the air and evenly distribute heated air across the conveyor belt on which the product rides.

  • Page 11: Air Fingers

    Manifold This is accomplished with use of hot air fingers inside the oven. The oven can accommodate up to 4 bottom air fingers and 4 top air fingers. Standard PS200-R68 Series ovens have 4 bottom fingers and 2 top fingers.
  • Page 12 End Stop Front Window Removable Jet Fingers Control (Inside Boxes Oven) Removable End Plugs Removable Crumb Pans Locking Casters (Rear Casters are not locking casters) Figure 1-4. Component Location Machinery Compartment Conveyor Motor Removable Conveyor Removable Drip Pans (Inside Oven)

  • Page 13: Component Function

    Figure 1-5. Conveyor Drive Motor B. Fan The fan is located at the rear of the oven. This fan forces heated air through the fingers. The fan switch has two positions and must be "on" for oven warm up and bake and for the conveyor to run.

  • Page 14: Air Fingers

    It must be assembled onto the NOTE: On a PS200-R68 Series Red Lobster oven the 2 upper fingers (M3) have 3 rows of holes in the outer plate and a non-columnating inner plate. The 4 bottom fingers (M6) have 6 rows of holes completely across the inner and outer plates.

  • Page 15: Section 2 Installation

    CAUTION: A minimum clearance of 0" from non-drive end of oven to wall, 18" from drive end of oven to wall and 6" from rear wall to air openings at rear of unit must be maintained.

  • Page 16: Type Of Installation

    SECTION 2 INSTALLATION TYPE INSTALLATION PS200-R68 Single Gas Oven PS200-R68 Single Electric Oven PS200-R68 Double Gas Oven PS200-R68 Double Electric Oven PS220-R68 Single Gas Oven PS220-R68 Single Electric Oven PS220-R68 Double Gas Oven PS220-R68 Double Electric Oven PS224-R68 Single Gas Oven...

  • Page 17: Installation Section

    PARTS LIST FOR SERIES PS200-R68 GAS OVEN (Two required for double oven) ITEM PS200-R68 PS220-R68 PART NO. PART NO. 22361-0005 22361-0005 23115-0010 23115-0010 31006 30849 30830 30830 30796 30796 88910-0008 88910-0008 1002040 1002040 33900-0032 33900-0081 42400-0089 49400-0090 23125-0002 23125-0002 23153-0005...
  • Page 18 22450-0228 30042 30039 31319 31320 32116 21516-0001 32227 Not Shown 1 32023 Figure 2-2. Series PS200-R68 Single and Double Oven Option Kits PS200-R68, P/N 31360 PS220-R68, P/N 30752 PS224-R68, P/N 49025-0016 PS220-R68 PS224-R68 DESCRIPTION PART NO. PART NO. 37900-0184 35900-0411...

  • Page 19: Dimension Drawing Of Oven

    RECOMMENDED MINIMUM CLEARANCES: Rear of Oven to Wall - 3" (76mm) Non-Drive End of Oven to Wall - 0" Drive End of Oven to Wall - 18" (457mm) OVEN VENT - GAS OVEN ONLY 2" x 3" (50mm x 75mm) 1”...

  • Page 20: Control Box And Cable Installation

    SECTION 2 INSTALLATION II. CONTROL BOX AND CABLE INSTALLATION CAUTION: When attaching cables turn the circuit breakers off. A. Install the control boxes, wireway and cables as shown in Figure 2-5. B. Install the "UPPER" and "LOWER" labels as shown. "UPPER"...

  • Page 21: Flue Vent Installation

    III. FLUE VENT INSTALLATION A. Install the flue vent: (Gas oven only) NOTE: On a single oven the flue is factory mounted. Flue Rear View Figure 2-5. Single Oven Flue Installation B. On a double oven install the flue extension and flue offset by sliding it down over the lower flue.

  • Page 22: Gas Oven Rough-In

    Runs over 200 ft. consult factory Propane: 1-1/2" (38mm) ID for 1 or 2 oven cavities with runs up to 200 ft.(61m). 2" (51mm) ID for 3 or 4 oven cavities with runs up to 200 ft.(61m). Must be a dedicated line.

  • Page 23: Electric Oven Rough-In

    ELECTRIC OVEN ROUGH-IN UTILITY ROUGH-IN DIMENSIONS AND POSITIONING FOR PS200-R68 SERIES OVENS CAUTION IT IS REQUIRED THAT THE OVEN BE PLACED UNDER A VENTILATION HOOD FOR ADEQUATE AIR SUPPLY AND VENTILATION. ELECTRICAL SUPPLY PROVIDED BY CUSTOMER DO NOT USE CONDUIT...

  • Page 24: Ventilation Guidelines

    SECTION 2 INSTALLATION V. VENTILATION GUIDELINES A mechanically driven ventilation system is required for the PS200-R68 Series Middleby Marshall conveyorized gas 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 25: Electric Supply For Gas Heated Ovens

    The power burner will not operate and gas will not flow through the burner without electric power. No attempt should be made to operate the oven during power failure.This oven is to be operated only on the type of gas as shown on Middleby...

  • Page 26: Electric Supply For Electrically Heated Ovens

    5 wire, 3 phase only. They are pre-wired at the factory and only one common connection is necessary. A standard oven is a 5 wire system (3 hot, 1 neut, 1 grd), it will not have a stepdown transformer. The neutral wire is combined with one 208-240 VAC, 3 phase leg to provide a 110V control circuit.

  • Page 27: Gas Supply For Gas Heated Ovens

    PS200-R68 or 200,000 BTU per hour for a PS220-R68 and PS224-R68. RECOMMENDED SUPPLY PIPE SIZE: Natural- 2" (51mm) ID for 1 or 2 oven cavities with runs up to 200 ft.(61m). 2-1/2" (64mm) ID for 3 or 4 oven cavities with runs up to 200 ft.(61m) Must be a dedicated line.
  • Page 28 SECTION 2 INSTALLATION 1. The oven and its individual manual shutoff valve (located at the left rear of the oven) must be discon- nected from the gas supply piping system during any pressure testing of that system at test pressure in excess of 1/2 psig (3.45 kPA).

  • Page 29: Conveyor Backstop And End Stop Installation

    X. CONVEYOR BACKSTOP AND END STOP IN- STALLATION Locate the conveyor backstop and end stop in the installation kit. Install the backstop and end stop at the exit end of the oven. Refer to Figure 2-14. Installing Backstop and End Stop Outlet Pressure...
  • Page 30 SECTION 2 INSTALLATION NOTES:...

  • Page 31: Section 3 Operation

    SECTION 3 OPERATION SECTION 3 OPERATION I. CONTROLS AND COMPONENTS Temperature Controller Conveyor Speed Control Upper Oven Lower Oven Control Box Control Box Blower Switch Conveyor Switch Heat Switch Figure 3-1. PS200-R68 Series Control Functions...

  • Page 32: Component Information And Location

    To protect the blower motor and bearings a thermo- static override is built into the oven. If the temperature inside the oven is over 180° F. (82° C.) the main blower and conveyor will continue to run even when the blower switch is turned to the off position.

  • Page 33: Conveyor

    Refer to Figure 3-4 & 3-5. To check conveyor speed place an item at the product entrance end of oven bake chamber as shown. Time how long it takes for the leading edge of the item to go from the entrance end of the bake chamber to the exit end and this will be your conveyor speed.

  • Page 34: Operation

    1/2 hour is turned on it goes through a 15 second purge cycle. The burner blower motor will not operate during the time the main fan is purging the oven. After 15 seconds the burner blower motor starts, which can be detected by feeling a slight vibration when touched.
  • Page 35 SECTION 3 OPERATION Middleby Marshall HEAT S E T P T FUNCTION DISPLAY RESET SET UP Temperature Controller Conveyor Speed Control Lower Right Lower Blank Left Blank ˚C Blower Switch Conveyor Switch Heat Switch Figure 3-6. Control Panel...

  • Page 36: Temperature Controller Operation Instructions

    1. UNLOCKING SET POINT. The temperature controller set point must be 450°F (232.2°C) for the upper oven and 350°F (176.7°C) for the lower oven. To raise or lower the set point on a Red Lobster oven the set point must first be unlocked by pressing the Lower Left Blank and the Lower Right Blank keys simultaneously.
  • Page 37 180°F (82°C). The “2” will appear only when the oven is initially heating up and has not yet reached 180°F (82°C) or the heat switch is turned off and the oven has cooled down below 180°F (82°C).

  • Page 38: Start Up Procedures - Electric Ovens

    The cooling fan, located at the rear of the machinery cabinet blows air into and through the cabinet. Air is exhausted out the back of the oven. A cooling fan is also located in the bottom of the control box to draw air through the rear louvers and out the bottom.

  • Page 39: Shut Down (Gas Or Electric Ovens)

    TIME OF DELIVERY- Time Of Delivery is the amount of elapsed time between the period when the Leading edge of a product enters the oven and the Trailing edge of the product is fully discharged and is ready to be delivered to the customer.
  • Page 40 SECTION 3 OPERATION NOTES:...

  • Page 41: Section 4 Maintenance

    Never disassemble or clean the oven interior with the fan switch or any other part of the oven turned "on". NOTICE If the oven is to be removed from it's installed location for servicing, the following procedure is to be implemented. 1. Shut off main manual gas valve.

  • Page 42: Crumb Pans

    Never disassemble or clean the oven with the fan switch or any other part of the oven turned "on". II.MAINTENANCE WEEKLY - Oven Disassembly and Cleaning Use the following instructions to clean the oven interior once a week. To clean the interior 2 people are required to Conveyor...
  • Page 43 Move slowly and use caution as the conveyor chain and the drive sprocket can be easily damaged. Figure 4-6. 6. Remove the lower end plug from each end of the oven. Refer to Figure 4-3.

  • Page 44: Oven Interior Disassembly

    3.Remove the air fingers by pulling the fingers at the back side and pulling straight out. The finger assemblies should not be disas- sembled at this time. 4. Remove the 3 drip pans from the bottom of the oven. Refer to Figure 4-9...

  • Page 45: Window Disassembly For Cleaning

    1. Remove the window by opening it and unscrewing the window knobs from each end. Place the window knobs on top of the oven in a cup so they can be easily found the next day. 2. Push the window all the way inside the oven, making sure it is clear of the frame.
  • Page 46 Figure 4-13. Then place the fingers in the soak bin by placing the slanted sides of the fingers together to conserve space as shown in Figure 4-13. 3. Repeat Steps a and b for the second oven. Refer to Figure 4-14.

  • Page 47: Cleaning Parts That Were Soaked Overnight

    Drip Pans E. Cleaning parts that were soaked overnight. Cleaning takes 2 people. One to clean the oven and one to clean the parts. You will need: • Boots • Rubber Gloves • Steel brush • Kote Spray • Squirt bottle filled with water •...
  • Page 48 When cleaning finger assemblies check one assembly at a time to see if the inner plate needs scrubbing. Disassemble only one finger at a time and after cleaning the inner plate and the manifold, reassemble the finger before disassembling the next finger. M3RN Finger RED LOBSTER FINGER CONFIGURATION IN OVEN Full Blank M3RN Product Direction (Either Direction) Figure 4-16.

  • Page 49: Cleaning Interior Of Oven

    Figure 4-19. F. Cleaning interior of oven. 1. Use the squirt bottle to spray the inside of oven with water. Do not spray into fan areas. 2. Wipe off all interior surfaces with damp grill pad. Use your black pad and putty knife to loosen any baked on material.

  • Page 50: Oven Reassembly

    SECTION 4 MAINTENANCE 3. Clean the oven exterior as needed and dry the oven inside and out. 4. Spray all interior surfaces, except the fan area, with Kote. Cover all areas well. Refer to Figure 4-20. Be sure the oven is dry before spraying.
  • Page 51 2. Reassemble bottom fingers into oven first by pushing in on their back side. Refer to Figure 4-16 for correct finger position in oven. IMPORTANT: Only M6 fingers fit in the bottom row. All M3 finger cover plates have extended lips at front. This extended lip will not allow these fingers to be installed in the bottom row.
  • Page 52 SECTION 4 MAINTENANCE Finger Tab on Outer Plate of Finger Located in Groove Finger Tab on Outer Plate of Finger Located in Groove Finger Tab on Outer Plate of Finger Located in Groove Incorrect- Too Much Space Blank Plate Tab To Rest End Plug On Blocking Incorrect-...
  • Page 53 6. Using 2 people install the conveyor. a. Lift the conveyor and start it into the drive end of the oven. The drive end of the oven is the end with the machinery compartment at- tached. Slide the conveyor along the side guides until the crumb tray slide falls into place at the opposite end.
  • Page 54 Figure 4-26. c. The angle plate located on the underside of the conveyor must be against the lower end plug. This is true on both ends of oven. d. Reassemble conveyor drive chain cover.
  • Page 55 NOTE: Oven conveyor belt must be cool when adjusting belt. Do not adjust belt if HOT. AA. With the conveyor assembly in the oven, stand at one end of conveyor and check tension by lifting the conveyor belt at the center of the oven chamber opening. The belt should not lift higher than 3 to 4 inches (76mm to 102mm).

  • Page 56: Maintenance - Every 3 Months

    A. Cleaning fan motor NOTE: It is recommended that step "A" thru "D" be performed by an authorized Middleby Marshall Service Agent. To gain access to the fan motor, open the machinery compartment door by removing three screws. Clean the fan motor, burner motor, conveyor motor and the surrounding area using either compressed air or CO the motor compartment and vents inside the motor.

  • Page 57: Checking And/Or Replacing Main Blower Fan Belt

    Remove 2 Screws C. Checking and/or replacing main blower fan belt 1. Check the main blower fan belt for proper tension and wear. To gain access you must remove the two (2) screws on the bottom lip of rear shroud along with the two (2) screws on the cooling fan guard plate.

  • Page 58: Main Blower Fan Shaft Bearing Lubrication

    Over greasing will damage bearing seals which will accelerate grease loss and shorten bearing life. Wipe off any excess grease on and around the bearing. Replace rear shroud, oven will not operate without the rear shroud in place. Figure 4-35.

  • Page 59: Maintenance - Every 6 Months

    IV. MAINTENANCE - EVERY 6 MONTHS NOTE: It is recommended that the 6 Month Maintenance schedule be performed by an Authorized Middleby Marshall Service Agent. and locked out or tagged out before attempting A. Check brushes on D.C. conveyor motor, when worn to less than 3/32" (2.2mm) replace.
  • Page 60 SECTION 4 MAINTENANCE NOTES:...

  • Page 61: Section 5 Troubleshooting

    Refer to Operation Set conveyor speed Section for proce- control at correct setting. dure to set tempera- ture correctly. Verify food preparation process. If products still cook incor- rectly call your local Middleby Marshall Service Agency.
  • Page 62 (93°C) within 15 minutes the temperature controller will flash "FAILSF". To reset the tempera- ture controller turn the blower switch off for 30 seconds. Try restarting the oven again. If the oven will not heat call your local Middleby Marshall Service Agency.
  • Page 63 Refer to Maintenance Section for checking procedure. Check that drive sprocket is tight. If conveyor still will not run contact your local Middleby Marshall Service Agency. PROBLEM OVEN WILL NOT TURN ON WHEN THE SWITCHES ARE TURNED ON Check if circuit breakers are turned on.
  • Page 64 SECTION 5 TROUBLESHOOTING PROBLEM BLOWER MOTORS RUNNING BUT LITTLE OR NO AIR AT FINGERS Fingers assembled incor- rectly after cleaning...

  • Page 65: Section 6 Parts List

    FIGURE NO. DESCRIPTION Oven Panels, Window and Legs Exploded Drawing Air Finger Exploded Drawing Control Panel Exploded Drawing Blower and Shroud Exploded Drawing Conveyor Exploded Drawing Gas Burner and Piping Assembly Exploded Drawing Machinery Compartment Exploded Drawing Electric Oven Electrical Panel Drawing...

  • Page 66: Oven Panels, Window And Legs Exploded Drawing

    20 22 OVEN PANELS, WINDOW AND LEGS FIGURE 6-1...
  • Page 67 OVEN PANELS, WINDOW AND LEGS PS200-R68 PS220-R68 ITEM PART PART QTY. 49400-0160 31314 35900-0285 35900-0371 30261 30420 21416-0005 21416-0005 2000346 2000346 49400-0161 49400-0244 35900-0286 35900-0472 30264 30514 21416-0005 21416-0005 2000346 2000346 21296-0002 21296-0002 21182-0006 21182-0006 30278 30278 21296-0005 21296-0005 35900-0043...
  • Page 68 FIGURE 6-2 AIR FINGERS...
  • Page 69 SECTION 6 PARTS LIST...

  • Page 70: Control Panel Exploded Drawing

    11,13 11,13 12,13 FIGURE 6-3 CONTROL PANEL...
  • Page 71 SECTION 6 PARTS LIST...
  • Page 72 BLOWER AND SHROUD FIGURE 6-4...
  • Page 73 SECTION 6 PARTS LIST...
  • Page 74 23 12 FIGURE 6-5 CONVEYOR Right Hand Drive Oven Shown. All components are reversed for Left Hand Drive Oven 28,29 24 25...
  • Page 75 SECTION 6 PARTS LIST...

  • Page 76: Gas Burner And Piping Assembly Exploded Drawing

    FIGURE 6-6 GAS BURNER AND PIPING ASSEMBLY Cap Screw Silver - Nat. Black - Propane Regulator Spring Silver - Nat. Adjustment Screw Red - Propane Gas Conversion Kit 4,30...
  • Page 77 AIR SHUTTER KIT 27030-0005 FUSE HOLDER WITH FUSE (1 AGC) 28091-0017 1/2" SOLENOID VALVE 23151-0032 1/2" x 3" NIPPLE - BLK, R.H. DRIVE ONLY 31315 1/2" x 31" PIPE, UPPER OVEN ONLY 31238 1/2" x 4" PIPE, LOWER OVEN ONLY...

  • Page 78: Machinery Compartment Exploded Drawing

    23,24 FIGURE 6-7 MACHINERY COMPARTMENT...
  • Page 79 SECTION 6 PARTS LIST...

  • Page 80: Electric Oven Electrical Panel Drawing

    FIGURE 6-8 ELECTRIC OVEN ELECTRIC PANEL...
  • Page 81 ELECTRIC OVEN ELECTRIC PANEL ITEM PART QTY. DESCRIPTION 37900-0097 ELECTRIC PANEL W/O COMPONENTS 37900-0096 BRACKET - ELECTRIC PANEL 27480-0001 POWER DISTRIBUTION BLOCK - 2 POLE 15028707 GROUND LUG 27021-0016 FUSE BLOCK - 3 POLE, 60 AMP, 600V, CLASS T 28150-0130...

  • Page 82: Junction Box And Export Transformer Exploded Drawing

    Transformer FIGURE 6-9 JUNCTION BOX AND EXPORT TRANSFORMER Terminal Block Ground...
  • Page 83 JUNCTION BOX AND EXPORT TRANSFORMER ITEM PART QTY. DESCRIPTION 28082-0010 TRANSFORMER .75 KVA 240-480V EXPORT ONLY 28082-0011 TRANSFORMER 1.0 KVA 190-380V EXPORT ONLY 27083-0008 BOX CONNECTOR 1/2" x 50° 35900-0147 CONDUIT 1/2" x 6" 27292-0009 JUNCTION BOX 4" x 4" A3333 BOLT 1/4"-20 x 3/4"...
  • Page 84 SECTION 6 PARTS LIST NOTES...

  • Page 85: Section 7 - Electrical Schematics

    SECTION 7 ELECTRICAL SCHEMATICS SECTION 7 ELECTRICAL SCHEMATICS...

  • Page 86: Gas Oven Schematic, 208-240V,50/60Hz,1Ph,4W

    Relay Coil XFMR 115V J1-14 Burner Blower SERIES PS200-R68 GAS OVEN SCHEMATIC 208-240V Main Blower Motors, 50/60Hz, 120V Control Circuit, 1 Ph, 4.1 Amp Draw, 3 Pole, 4 Wire (2 hot, 1 neut, 1 grd) Pick-up D.C. Control AC SP...

  • Page 87: Oven Control Box Cables

    24 pin cable, Both connectors at Machinery Compartment, female 4 3 2 1 7 6 5 12 11 10 24 23 22 Pin #’s 1-12 Thumbwheel Ribbon Cable starting with Pin #1 - blue Pin #22 Red, Thermocouple Pin #23 Wht, Thermocouple Pin #24 Ground 14 pin cable Male end...

  • Page 88: Section 7 Electrical Schematics

    SECTION 7 ELECTRICAL SCHEMATICS Middleby Marshall A MIDDLEBY COMPANY Middleby Marshall Inc. • 1400 Toastmaster Drive • Elgin, IL 60120 • (708) 741-3300 • FAX (708)741-4406 National Service Cooperative 1-800-298-1862 Middleby Corporation Service Hotline 1-800-238-8444...

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