Middleby Marshall PS540 (Double) manual

©200 6 Middleby Marshall Inc. Middleby Middleby Middleby Middleby Middleby Marshall Marshall Marshall Marshall Marshall A MIDDLEBY COMPANY PS540-Series Electric Ovens: English owner's operating & installation manual PS540-Series O VENS Model PS540E PS540 (Triple) PS540 (Double) Part No. 51415 Price $30.00 P: 10/06 ® PS540 (Single)[...]

ii W ARNING FOR Y OUR SAFETY , DO NO T ST ORE OR USE GASOLINE OR O THER FLAMMABLE V APORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY O THER APPLIANCE. W ARNING Improper installation, adjustment, alteration, service, or maintenance can cause pr oper ty damage, injury , or death. Read the installation, operation, and maintenance instructions thorough[...]

iii MIDDLEBY MARSHALL INC. O VEN LIMITED W ARRANTY (Non U .S.A.) The Seller warrants equipment manufactured by it to be free from defects in material and workmanship for which it is responsible. The Seller’s obligation under this warranty shall be limited to replacing or repairing, at Seller’s option, without charge, F.O.B. Seller’s factory, [...]

iv NO TE 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. TABLE OF CONTENTS Page SECTION 1 I. MODEL IDENTIFICATION .............................................. 1 SERIES PS540 ELECTRICAL SPECIFICATIONS ............. 2 II. PRINCIPLE OF AIR FLOW ....................[...]

SECTION 1 DESCRIPTION 1 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. A single PS540-Series Oven (Figure 1-1) is mounted on a base pad with legs and casters. A doub[...]

2 SECTION 1 DESCRIPTION PS540 SERIES OVEN SPECIFICATIONS Conveyor Belt Width 32 ″ (813mm) Heating Zone Length 40-1/2 ″ (1028mm) Baking Area Square Feet 9 sq. ft. (0.84 sq. m.) Overall Dimension Standard Single Oven w/Legs 80 ″ (2032mm) L × 61-5/16 ″ (1557mm) W × 47-5/16 ″ (1202mm) H × Overall Dimension Double Oven 80 ″ (2032mm) L × [...]

SECTION 1 DESCRIPTION 3 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 foo[...]

4 SECTION 1 DESCRIPTION Series ovens used to bake pizza have four bottom fingers and two top fingers. For special product baking require- ments, a number of other styles of fingers and finger arrangements are available from the factory. NOTE: Some customers have a predetermined finger arrangement. If you have any questions pertaining to the finger [...]

SECTION 1 DESCRIPTION 5 III. COMPONENT FUNCTION (Figure 1-6) Figure 1-6. PS540-Series Oven Components Locations[...]

6 SECTION 1 DESCRIPTION III. COMPONENT FUNCTION A. Conveyor Motor and Conveyor Belt The conveyor belt is driven by a variable-speed electric motor (Figure 1-7) operating through a gear reducer. The motor speed is controlled by a digital control. The stain- less-steel wire belt can travel in either direction at variable rates ranging from 3 minutes [...]

SECTION 1 DESCRIPTION 7 Figure 1-8. Cooling Fan[...]

8 SECTION 1 DESCRIPTION Half Blank Plate Blank Plate Outer Plate Inner Plate Finger Manif old Assembly Baffle 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.[...]

SECTION 2 INSTALLATION 9 SECTION 2 INST ALLA TION NOTE: The oven, when installed, must be electrically grounded in accordance with local codes, or in the ab- sence of local codes, with the National Electrical Code (NEC), or ANSI/NFPA70. NO TE There must be adequate clearance between the oven and any adjacent combustible con- struction. Clearance mu[...]

10 SECTION 2 INSTALLATION PS540 OVEN INSTALLATION REQUIRED KITS AND EQUIPMENT T YP E PS540 PS540 Single PS540 Double PS540 Double PS540 Triple O F Gas Oven Oven Option Oven Option Oven Option Oven Option INSTALLATION Installation Base w/15 ″ Legs, Base w/6 ″ Legs, Base w/Casters Base w/Casters Kit P/N Casters & Top Casters & Top & T[...]

SECTION 2 INSTALLATION 11 PARTS LIST FOR PS540 SERIES SINGLE OVEN OPTION - BASE w/15 ″ ″ ″ ″ ″ LEGS & TOP P/N 34832 ITEM NO . QT Y PART NO. DESCRIPTION 1 1 37900-0025 COMPLETE BASE WELDMENT 2 4 37900-0024 TOP PLATE, LEG WELDMENT 3 2 22290-0009 SWIVEL CASTER W/BRAKE FLAT PLATE 4 2 22290-0010 SWIVEL CASTER FLAT PLATE 5 32 220373 3 / 8 ?[...]

12 SECTION 2 INSTALLATION PARTS LIST FOR PS540 SERIES DOUBLE OVEN OPTION - BASE w/6 ″ ″ ″ ″ ″ LEGS, CASTERS & TOP P/N 34833 ITEM NO . QT Y PART NO. DESCRIPTION 1 1 37900-0025 COMPLETE BASE WELDMENT 2 4 37900-0102 TOP PLATE, LEG WELDMENT 3 2 22290-0009 SWIVEL CASTER W/BRAKE FLAT PLATE 4 2 22290-0010 SWIVEL CASTER FLAT PLATE 5 32 220373[...]

SECTION 2 INSTALLATION 13 PARTS LIST FOR PS540 SERIES TRIPLE OVEN OPTION - BASE w/CASTERS & TOP P/N 51139 ITEM NO . QT Y PART NO. DESCRIPTION 1 1 54606 COMPLETE BASE WELDMENT 2 4 45209 QUAD OUTRIGGER WELDMENT 3 2 22290-0009 SWIVEL CASTER, W/BRAKE FLAT PLATE 4 2 22290-0010 SWIVEL CASTER, FLAT PLATE 5 4 45206 INSERT,QUAD ADJUSTMENT FOOT 6 4 45205[...]

14 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 ″[...]

SECTION 2 INSTALLATION 15 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 ″[...]

16 SECTION 2 INSTALLATION RESTRAINT CABLE INSTALLATION Install the restraint cable assembly on the oven, as shown in Figure 2-6. Figure 2-7. MODEL TRIPLE 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 ″ F[...]

SECTION 2 INSTALLATION 17 WARNING DO NOT USE CONDUIT OR GAS LINE FOR GROUND CONNECTION. CAUTION IT IS REQUIRED THAT THE OVEN BE PLACED UNDER A VENTILATION HOOD FOR ADEQUATE AIR SUPPLY AND VENTILATION. ELECTRIC AND GAS SUPPLY TO BE PROVIDED BY CUSTOMER ELECTRICAL SAFETY SWITCH 15 Amp circuit breaker / fused disconnect switch with lockout/tagout elec[...]

18 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. Following are the suggested[...]

SECTION 2 INSTALLATION 19 III. ELECTRICAL CONNECTION INFORMATION FOR PS540-SERIES OVENS. WARNING Authorized supplier personnel normally accom- plish the connections for the ventilation system, electric supply, and gas supply, as arranged by the customer. Following these connections, the factory-authorized installer can perform the initial startup o[...]

20 SECTION 2 INSTALLATION VI. CONVEYOR REAR STOP AND END STOP INSTALLATION Locate the conveyor rear stop and end stop in the installation kit. Install the rear stop and end stop at the exit end of the oven. See Figure 2-13. Middleby Marshall Conveyor Rear Stop Conveyor End Stop Figure 2-13. Installing Rear and End Stops[...]

SECTION 3 OPERATION 21 SECTION 3 OPERA TION I. CONTROL FUNCTIONS WARNING A possibility of injury from rotating parts and electric shock exists in this oven. Never disassemble or clean the oven with the BLOWER switch or any other oven control turned “ON” or “I”. Turn “OFF” or “O” and lockout or tagout all electric power to the oven b[...]

22 SECTION 3 OPERATION I I . COMPONENT INFORMATION AND LOCATION (Figures 3-1 and 3-2) A. Door Safety Switch The Door Safety Switch is located at the lower left side of control panel opening. Opening the control panel door permits this switch to open, disconnecting power to all electrical controls. CAUTION Do NOT touch the wires going to this safety[...]

SECTION 3 OPERATION 23 E. Conveyor The on-off switch for the conveyor motor is on the control panel. Also on the control panel is the digital conveyor speed control. The digital control can be adjusted from 3 min. to 30 min. bake time (conveyor speed). Refer to Figure 3-3. Conveyor speed is measured by the amount of time it takes for an item to go [...]

24 SECTION 3 OPERATION WARNING OVEN MUST BE KEPT CLEAR OF COMBUSTIBLES AT ALL TIMES. III. STEP-BY-STEP OPERATION Control Panel (On split belt ovens, two conveyor speed controls are mounted on the control panel.) A. Startup Procedures Daily Startup 1. Turn the BLOWER switch (Figure 3-6) to the “ON” or “I” position. This starts the main blowe[...]

SECTION 3 OPERATION 25 4. Open the oven window. Figure 3-6. Control Panel[...]

26 SECTION 3 OPERATION CAUTION In case of power failure, turn all switches to the “OFF” ("O") position, open the oven window, and remove the product. After the power has been restored, perform the normal startup procedure. IF THE OVEN WAS SWITCHED OFF FOR LESS THAN 5 MINUTES, WAIT FOR AT LEAST FIVE MINUTES BEFORE RE- STARTING THE OVEN[...]

SECTION 3 OPERATION 27 Display Shows the Set Point or the Actual T em- perature in degrees Fahrenheit (F) or Celsius (C). "SP LOCK" Light 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 Qui[...]

28 SECTION 3 OPERATION IV . QUICK REFERENCE: TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION The oven temperature ex- ceeded 650°F (343°C), and the burner was automati- cally shut down. • Follow the procedures under Daily Shutdown Procedures in this section to shut down the oven. Contact your Middleby Marshall Authorized Service Agent to determine and[...]

SECTION 4 MAINTENANCE 29 SECTION 4 MAINTENANCE WARNING Possibility of injury from rotating parts and electrical shock exist in this oven. Turn off and lockout or tagout electrical supply to oven(s) before attempting to disassemble, clean or service oven(s). Never disas- semble or clean the oven with the blower switch or any other part of the oven t[...]

30 SECTION 4 MAINTENANCE I. MAINTENANCE - DAILY A. Exterior Everyday you should clean the outside of the oven with a soft cloth and mild detergent. WARNING Never use a water hose or pressurized steam cleaning equipment when cleaning the oven. B. Cooling Fan 1. TWO COOLING FAN GRILLES AT THE REAR OF EACH OVEN CONTROL COMPARTMENT MUST BE CLEANED DAIL[...]

SECTION 4 MAINTENANCE 31 Figure 4-3. II. MAINTENANCE - MONTHLY NOTE: The oven interior may require cleaning more than once a month depending on the volume of baking. 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 saturatio[...]

32 SECTION 4 MAINTENANCE 4. Remove conveyor drive chain cover as shown. 5. Remove tension from drive chain by lifting and pushing the conveyor slightly into the oven. Remove drive chain from conveyor drive sprocket as shown. NOTE: The split belt conveyor assembly can only be removed from the drive end of the oven. 6. Begin sliding conveyor out of t[...]

SECTION 4 MAINTENANCE 33 B. Air Fingers Disassembly For Cleaning 1. As the air fingers are removed use a felt pen to mark all parts of the fingers. This includes the finger manifold, inner plate and the outer plate (refer to Figure 1-9). If a blank or choke plate is used, mark that plate also. Fingers are marked in the order shown; as viewed from t[...]

34 SECTION 4 MAINTENANCE 6. To remove the inner plate, pull the plate out and then up. Figure 4-12. 7. The outer finger plate is stainless and may be cleaned by either soaking in a hot, strong detergent solution or using a caustic cleaner. The conveyor belt can also be cleaned in the same way. Figure 4-13. Standard Lower Finger Figure 4-14. Standar[...]

SECTION 4 MAINTENANCE 35 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. Keep your fingers clear so you won’t pinch them. Figure 4-18. 4. Repla[...]

36 SECTION 4 MAINTENANCE 5. Install fingers and blank plates correctly with edges interlocked and no space between edges. Figure 4-21. Top Finger Incorrect - Too Much Space Blank Plate Tab on Outer Plate of Finger Located in Groove Top Finger Incorrect - Too Much Space Blank Plate Tab on Outer Plate of Finger Located in Groove Top Finger Correct - [...]

SECTION 4 MAINTENANCE 37 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. Figure 4-23.[...]

38 SECTION 4 MAINTENANCE G. Checking Conveyor Belt Tension WARNING Oven conveyor belt must be cool when adjusting belt. Do not adjust belt if HOT. 1. With the conveyor assembly in the oven, stand at one end of conveyor and check tension by lifting the conveyor belt at the center of the oven chamber opening. The belt should not lift higher that 3 ?[...]

SECTION 4 MAINTENANCE 39 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. Figure 4-27. 2. Using long nose pliers, unhook master links at left end of conveyor as shown in Figure 4-28. Figure[...]

40 SECTION 4 MAINTENANCE I. Replacing Conveyor Belt If a section of the conveyor belt needs replacing it can be done with the conveyor assembly either in or out of the oven. The section of the conveyor belt furnished with the oven in the installation kit may then be used to replace a section. Follow the preceding procedure “H. Conveyor belt link [...]

SECTION 4 MAINTENANCE 41 4. Reassemble conveyor drive chain cover and then reassemble the bottom cover to the drive chain cover. Install both upper end plugs. Figure 4-37. III. MAINTENANCE - EVERY 3 MONTHS WARNING Shut OFF all electrical power and lock/tag out the switch before attempting maintenance work. Shut OFF gas supply to oven. NOTE: It is r[...]

42 SECTION 4 MAINTENANCE B. Electrical Terminals Open the control cabinet door by removing the three screws from the control cabinet door. Tighten all electrical control terminal screws including the electrical contactor terminal screws as shown in Figure 4-39. Figure 4-39. C. Ventilation Check that the air circulation throughout the oven is not bl[...]

SECTION 4 MAINTENANCE 43 E. Blower Fan Shaft Bearing Lubrication CAUTION Over-greasing damages the bearing seals and accelerates grease loss, which shortens bearing life. Wipe off any excess grease on and around the bearing. Reinstall the rear shroud to allow the oven to operate Grease the two (2) main blower fan shaft bearings (Figure 4-43), using[...]

44 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. Figure 4-49. 9. Loosen the split locking collar. Figure 4-50. 10. Remove driv[...]

SECTION 4 MAINTENANCE 45 12. Slide shaft assembly to right side, holding assembly in place. Slide split locking collar to the left side and tighten. 13. Slide rear conveyor drive sprocket onto shaft. Tighten the set screw of this drive sprocket until it extends into the hole of the hollow shaft. It should NOT touch the inner, solid shaft. Check to [...]

46 SECTION 4 MAINTENANCE PS540-SERIES ELECTRIC OVEN KEY SPARE PARTS KIT (Figure 4-56) ITEM PART NO. ENGLISH DESCRIPTION QUANTITY 1 47321 Temperature Controller 1 2 44687 Blower/Fan Motor 1 3 47797 Conveyor Drive Motor 1 4 37337 Conveyor Speed Control 1 5 33812-3 Thermocouple 1 6 41647 Module M420 1 7 50275 Burner & Motor Assembly 1 8 50239 Igni[...]

47 SECTION 5 TROUBLESHOOTING SECTION 5 TROUBLESHOO TING PROBLEM: PRODUCTS ARE OVERCOOKED OR UNDERCOOKED Check for correct setting of conveyor speed control. Set the conveyor speed control at correct setting. Check for correct setting on tempera- ture controller. Turn temperature control to correct setting. If products still cook incorrectly, call y[...]

SECTION 5 TROUBLESHOOTING 48 NO TES[...]

49 ENGLISH SECTION 6 PARTS LIST SECTION 6 - P AR TS LIST[...]

50 ENGLISH SECTION 6 PARTS LIST[...]

51 ENGLISH SECTION 6 PARTS LIST OVEN PANELS, WINDOW AND LEGS ITEM QTY. P/N DESCRIPTION 1 2 49947 UPPER END PLUG ASSEMBLY 2 2 49946 LOWER END PLUG ASSEMBLY 3 8 36452 WING NUT, PLASTIC 1/4-20 4 8 45449 E ND PLUG MOUNTING PLATE ASSEMBLY 5 16 21296-0005 SC R E W , H EX WS H HD 12-14 × 3/4 ″ , SS BSD 6 1 49905 CONVEYOR CHAIN COVER 7 2 50637 EYEBROW 8[...]

52 ENGLISH SECTION 6 PARTS LIST[...]

53 ENGLISH SECTION 6 PARTS LIST CONTROL PANEL[...]

54 ENGLISH SECTION 6 PARTS LIST[...]

55 ENGLISH SECTION 6 PARTS LIST BLOWER AND SHROUD[...]

56 ENGLISH SECTION 6 PARTS LIST[...]

57 ENGLISH SECTION 6 PARTS LIST CONVEYOR ITEM QTY. P/N DESCRIPTION 1 1 47042 SINGLE CONVEYOR 80 ″ EXCLUDES ITEMS 7, 8, 9, 12, 36 & 37 2 1 22450-0225 CONVEYOR BELT, 1/2P 32 ″ × 204 ″ 2.84/11 S 3 1 33900-0032 CO NVEYOR CHAIN, SS WIRE1 FT 4 1 51380 KIT, MASTER LINK, CONTAINS ((1) 33900-0016, (4) 33900-0017, (1) 33900-0018) 5 1 33900-0016 MA[...]

58 ENGLISH SECTION 6 PARTS LIST[...]

59 ENGLISH SECTION 6 PARTS LIST SPLIT BELT CONVEYOR ITEM QTY. P/N DESCRIPTION ITEM QTY. P/N DESCRIPTION 1 1 50646 S PLIT CONVEYOR 50/50 80 ″ EXCLUDES ITEMS 7, 8, 9, 12, 36 & 37 2 1 22450-0226 CONVEYOR BELT, 1/2P 15 ″ × 146 ″ 2.86/5 SP 3 1 33900-0037 CO NVEYOR CHAIN, SS WIRE1 FT 4 1 51382 KIT, MASTER LINK, CONTAINS ((1) 33900-0016, (1) 33[...]

60 ENGLISH SECTION 6 PARTS LIST[...]

61 ENGLISH SECTION 6 PARTS LIST MACHINERY COMPARTMENT ITEM QTY. P/N DESCRIPTION 1 1 28021-0047 INTERLOCK SWITCH 10A NO2P 2 1 28021-0061 MOMENTARY SWITCH - 10A NO 2 POLE 3 1 44687 MOTOR 1/2 HP 4 1 49953 MOTOR MOUNTING BRACKET WELDMENT 5 1 50449 M O T O R S U P PORT BRACKET 6 8 1513D8805 SCREW, HEX HD 3/8 ″ -16 × 3/4 ″ - NP 7 8 21422-0001 LOCK W[...]

62 ENGLISH SECTION 6 PARTS LIST NOTES[...]

63 SECTION 7 ELECTRICAL SCHEMATICS SECTION 7 ELECTRICAL SCHEMA TICS Wiring Diagram, E208-240 50/60, 3PH 4W PS540ES 50466C[...]

SECTION 7 ELECTRICAL SCHEMATICS 64 Wiring Diagram, E380-480 50/60, 3PH 5W PS540ES 50140C[...]

65 SECTION 7 ELECTRICAL SCHEMATICS Wiring Diagram, E380V 50/60, 3PH 5W PS540ES 50467C[...]

SECTION 7 ELECTRICAL SCHEMATICS 66 Wiring Diagram, E400-416V 50/60, 3PH 5W PS540ES 51068D[...]

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Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • USA • (847)741-3300 • FAX (847)741-4406 24-Hour Service Hotline: 1-(800)-238-8444 www .middleby .com Middleby is proud to support the Commercial Food Equipment Service Association (CFESA). We recognize and applaud CFESA's ongoing efforts to improve the qualit[...]