Instruction/ maintenance manual of the product PS540 Middleby Marshall
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©200 6 Middleby Marshall Inc. Middleby Middleby Middleby Middleby Middleby Marshall Marshall Marshall Marshall Marshall A MIDDLEBY COMPANY PS540-Series Gas Ovens: English owner's operating & installation manual PS540-Series O VENS Model PS540G PS540 (Triple) PS540 (Double) Part No.
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 POST , IN A PROMINENT LOCA TION, THE EMERGENCY PHONE NUMBER OF Y OUR LOCAL GAS SUPPLIER AND INSTRUCTIONS T O BE FOLLO WED IN THE EVENT Y OU SMELL GAS.
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.
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 .
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.
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.
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.
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.
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.
SECTION 1 DESCRIPTION 7 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.
8 SECTION 1 DESCRIPTION F. Air Fingers and Blank Plates - See Figure 1-9 F1. Air Fingers An Air Finger Assembly is made up of three parts: 1. Outer Plate - The Outer Plate is the removable covering with tapered holes, which direct the air stream onto the product being baked.
SECTION 2 INSTALLATION 9 SECTION 2 INST ALLA TION NOTE: In U.S.A., the oven installation must conform with local codes, or in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.
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 Opt.
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.
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.
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 OUTRIG.
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 .
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 .
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 .
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.
18 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.
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.
20 SECTION 2 INSTALLATION V. GAS SUPPLY FOR GAS HEATED OVENS WARNING During gas line pressure testing, observe the following precautions: 1. The oven and its individual shutoff valve MUST be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.
SECTION 2 INSTALLATION 21 To Gas Supply Pipe Full Flow Gas Shutoff Valve Flexible Hose Union 90-deg. ST. Elbow Appliance Connection (Male Nipple) The minimum gas line pressure at the input side of the full-flow gas shutoff valve, when the oven burner is operating on the high flame, MUST be, for natural gas, 6 ″ w.
22 SECTION 2 INSTALLATION NO TES.
SECTION 3 OPERATION 23 SECTION 3 OPERA TION I. CONTROL FUNCTIONS WARNING 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. WARNING A possibility of injury from rotating parts and electric shock exists in this oven.
24 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.
SECTION 3 OPERATION 25 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).
26 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 Initial Startup Check that the full-flow gas shutoff valve is “on”.
SECTION 3 OPERATION 27 Figure 3-6. Control Panel.
28 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.
SECTION 3 OPERATION 29 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.
30 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.
SECTION 4 MAINTENANCE 31 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).
32 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.
SECTION 4 MAINTENANCE 33 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.
34 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.
SECTION 4 MAINTENANCE 35 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.
36 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.
SECTION 4 MAINTENANCE 37 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.
38 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 Pl.
SECTION 4 MAINTENANCE 39 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.
40 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.
SECTION 4 MAINTENANCE 41 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.
42 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.
SECTION 4 MAINTENANCE 43 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.
44 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.
SECTION 4 MAINTENANCE 45 E. Blower Fan Shaft Bearing Lubrication CAUTION Over-greasing damages the bearing seals and accelerates grease loss, which shortens bearing life.
46 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.
SECTION 4 MAINTENANCE 47 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.
48 SECTION 4 MAINTENANCE PS540-SERIES GAS OVEN KEY SPARE PARTS KIT, p/n 36805 (Figure 4-56) ITEM PART NO. ENGLISH DESCRIPTION QUANTITY 1 47321 Temperature Controller 1 2 44687 Blower/Fan Motor 1 3 477.
49 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.
SECTION 5 TROUBLESHOOTING 50 NO TES.
51 ENGLISH SECTION 6 PARTS LIST SECTION 6 - P AR TS LIST.
52 ENGLISH SECTION 6 PARTS LIST.
53 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 .
54 ENGLISH SECTION 6 PARTS LIST.
55 ENGLISH SECTION 6 PARTS LIST CONTROL PANEL ITEM QTY. P/N DESCRIPTION 1 1 47321 COMBO BURST CONTROL, 4-20Ma 2 1 33812-3 THERMOCOUPLE, TYPE J SHIELDED 9.
56 ENGLISH SECTION 6 PARTS LIST.
57 ENGLISH SECTION 6 PARTS LIST BLOWER AND SHROUD ITEM QTY. P/N DESCRIPTION 1 1 51157 PULLEY, 1GRV 3.0PD AK32H 2 1 48855 WELDMENT, BRG BRACKET PS540G 3 22 220373 SCREW, HH 3/8 ″ - 16 × 1 ″ SS T 3.
58 ENGLISH SECTION 6 PARTS LIST.
59 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.
60 ENGLISH SECTION 6 PARTS LIST.
61 ENGLISH SECTION 6 PARTS LIST SPLIT BELT CONVEYOR ITEM QTY. P/ N DESCRIPTION ITEM QTY. P/ N DESCRIPTION 1 1 50646 SPLIT CONVEYOR 50/50 80 ″ EXCLUDES ITEMS 7, 8, 9, 12, 36 & 37 2 1 22450-0226 CONVEYOR BELT, 1/2P 15 ″ × 146 ″ 2.
62 ENGLISH SECTION 6 PARTS LIST.
63 ENGLISH SECTION 6 PARTS LIST GAS BURNER AND PIPING ASSEMBLY ITEM QTY. P/ N DESCRIPTION 1 1 50274 1 / 2 ″ GAS CONTROL VALVE (Conversion Required for Propane) 2 5 23153-0004 1/ 2 ″ CLOSE NIPPLE -.
64 ENGLISH SECTION 6 PARTS LIST.
65 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 1 499.
66 ENGLISH SECTION 6 PARTS LIST NOTES.
67 SECTION 7 ELECTRICAL SCHEMATICS SECTION 7 ELECTRICAL SCHEMA TICS Wiring Diagram, G208-240 50/60, 1PH 3W PS540 50141G.
SECTION 7 ELECTRICAL SCHEMATICS 68 NO TES.
69 SECTION 7 ELECTRICAL SCHEMATICS NO TES.
SECTION 7 ELECTRICAL SCHEMATICS 70 NO TES.
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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).
An important point after buying a device Middleby Marshall PS540 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Middleby Marshall PS540 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Middleby Marshall PS540 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Middleby Marshall PS540 you will learn all the available features of the product, as well as information on its operation. The information that you get Middleby Marshall PS540 will certainly help you make a decision on the purchase.
If you already are a holder of Middleby Marshall PS540, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Middleby Marshall PS540.
However, one of the most important roles played by the user manual is to help in solving problems with Middleby Marshall PS540. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Middleby Marshall PS540 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
