PS640 Series
Gas
Domestic & Std. Export
ENGLISH
P/N 60251
August 2007
PS640 Series Gas Ovens
Model:
• PS640G Gas
Combinations:
• Single Oven
• Double Oven (Two-Stack)
• Triple Oven (Three-Stack)
OWNER'S OPERATING AND
INSTALLATION MANUAL
for domestic and standard export ovens
©2007 Middleby Marshall Inc.
is a registered trademark of Middleby Marshall, Inc. All rights reserved.
Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • (847)741-3300 • FAX (847)741-4406
NOTICE:
This
Owner's Operating and Installation Manual should be given to the user. The operator of the oven should be
familiar with the functions and operation of the oven.
This manual must be kept in a prominent, easily reachable location near the oven.
Ovens are shipped from the factory configured for use with natural gas. If permitted by local, national and
international codes, at the time of installation the oven may be converted to propane gas operation. This conversion
requires the use of at Gas Conversion Kit that is supplied with the oven. For CE-approved ovens, the conversion is
described in the
included in the Gas Conversion Kit.
It is suggested to obtain a service contract with a Middleby Marshall Authorized Service Agent.
Installation
section of this Manual. For domestic and standard export ovens, instructions are
WARNING
POST, IN A PROMINENT LOCATION, THE EMERGENCY TELEPHONE NUMBER OF YOUR LOCAL GAS
SUPPLIER AND INSTRUCTIONS TO BE FOLLOWED IN THE EVENT YOU SMELL GAS.
Instructions to be followed in the event the user smells gas shall be obtained by consulting the local
gas supplier. If the smell of gas is detected, immediately call the emergency phone number of your
local Gas Company. They will have personnel and provisions available to correct the problem.
WARNING
FOR YOUR SAFETY, DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS
AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
WARNING
Improper installation, adjustment, alteration, service, or maintenance can cause
property damage, injury, or death. Read the installation, operation, and maintenance instruc-
tions thoroughly before installing or servicing this equipment.
IMPORTANT
An electrical wiring diagram for the oven is located inside the machinery compartment.
IMPORTANT
It is the customer’s responsibility to report any concealed or non-concealed damage to the
freight company. Retain all shipping materials until it is certain that the equipment has
not suffered concealed shipping damage.
NOTICE
CONTACT YOUR MIDDLEBY MARSHALL AUTHORIZED SERVICE AGENT TO INSTALL AND
PERFORM MAINENANCE AND REPAIRS AND IF NECESSARY TO CONVERT EQUIPMENT
FOR USE WITH OTHER GASES. AN AUTHORIZED SERVICE AGENCY DIRECTORY IS
SUPPLIED WITH YOUR OVEN.
NOTICE
Using any parts other than genuine Middleby Marshall factory manufactured parts relieves the manu-
facturer of all warranty and liability.
NOTICE
Middleby Marshall (Manufacturer) reserves the right to change specifications at any time.
NOTICE
The equipment warranty is not valid unless the oven is installed, started and demonstrated under the
supervision of a factory certified installer.
NOTICE
THIS EQUIPMENT IS ONLY FOR PROFESSIONAL USE AND SHALL BE USED
BY QUALIFIED PERSONNEL.
RETAIN THIS MANUAL FOR FUTURE REFERENCE.
Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 USA • (847)741-3300 • FAX (847) 741-4406
www.middleby.com
ii
Model No.
Modéle No.
Serial No.
Serié No.
Installation Date
Date d'installation
MIDDLEBY MARSHALL
N
O QUIBBLE LIMITED WARRANTY
(U.S.A. ONLY)
MIDDLEBY MARSHALL, HEREINAFTER REFERRED TO
AS “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, ANY
PART FOUND TO BE DEFECTIVE AND ANY LABOR AND
MATERIAL EXPENSE INCURRED BY SELLER IN REPAIRING OR REPLACING SUCH PART. SUCH WARRANTY
SHALL BE LIMITED TO THE ORIGINAL PURCHASER
ONLY AND SHALL BE EFFECTIVE FOR A PERIOD OF
ONE YEAR FROM DATE OF ORIGINAL INSTALLATION, OR
18 MONTHS FROM DATE OF PURCHASE, WHICHEVER
IS EARLIER, PROVIDED THAT TERMS OF PAYMENT HAVE
BEEN FULLY MET.
This warranty is valid only if the equipment is installed, started,
and demonstrated under the supervision of a factory-authorized installer.
Normal maintenance functions, including lubrication, cleaning, or customer abuse, are not covered by this
warranty
Seller shall be responsible only for repairs or replacements
of defective parts performed by Seller’s authorized service
personnel. Authorized service agencies are located in principal cities throughout the contiguous United States, Alaska,
and Hawaii. This warranty is valid in the 50 United States
and is void elsewhere unless the product is purchased
through Middleby International with warranty included.
.
The foregoing warranty is exclusive and in lieu of all other
warranties, expressed or implied. There are no implied
warranties of merchantability or of fitness for a particular purpose.
The foregoing shall be Seller’s sole and exclusive obligation
and Buyer’s sole and exclusive remedy for any action, including breach of contract or negligence. In no event shall
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.
This warranty is effective on Middleby Marshall equipment sold on, or after, February 15, 1995.
no quibble
MIDDLEBY MARSHALL INC.
OVEN LIMITED WARRANTY
(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,
any part found to be defective and any labor and material expense
incurred by Seller in repairing or replacing such part. Such warranty
is limited to a period of one year from date of original installation or
15 months from date of shipment from Seller’s factory, whichever is
earlier, provided that terms of payment have been fully met. All labor
shall be performed during regular working hours. Overtime premium
will be charged to the Buyer.
This warranty is not valid unless equipment is installed, started,
and demonstrated under the supervision of a factory-authorized installer.
Normal maintenance functions, including lubrication, adjustment of
airflow, thermostats, door mechanisms, microswitches, burners and
pilot burners, and replacement of light bulbs, fuses and indicating
lights, are not covered by warranty.
Any repairs or replacements of defective parts shall be performed by
Seller’s authorized service personnel. Seller shall not be responsible for any costs incurred if the work is performed by other than
Seller’s authorized service personnel.
When returning any part under warranty, the part must be intact and
complete, without evidence of misuse or abuse, freight prepaid.
Seller shall not be liable for consequential damages of any kind
which occur during the course of installation of equipment, or which
result from the use or misuse by Buyer, its employees or others of
the equipment supplied hereunder, and Buyer’s sole and exclusive
remedy against Seller for any breach of the foregoing warranty or
otherwise shall be for the repair or replacement of the equipment or
parts thereof affected by such breach.
The foregoing warranty shall be valid and binding upon Seller if and
only if Buyer loads, operates and maintains the equipment supplied
hereunder in accordance with the instruction manual provided to
Buyer. Seller does not guarantee the process of manufacture by
Buyer or the quality of product to be produced by the equipment
supplied hereunder and Seller shall not be liable for any prospective
or lost profits of Buyer.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF
ALL OTHER EXPRESS AND IMPLIED WARRANTIES WHATSOEVER. SPECIFICALLY THERE ARE NO IMPLIED WARRANTIES
OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE.
The foregoing shall be Seller’s sole and exclusive obligation and
Buyer’s sole and exclusive remedy for any action, whether in breach
of contract or negligence. In no event shall seller be liable for a sum
in excess of the purchase price of the item.
© 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
iii
TABLE OF CONTENTS
Page
SECTION 1 – DESCRIPTION ............................................ 1
I. OVEN USES ............................................................ 1
II. OVEN COMPONENTS ............................................ 1
A. Conveyor Motor Drive ................................... 1
B. Crumb Pans .................................................. 1
C. Conveyor ....................................................... 1
D. End Plugs ...................................................... 1
E. Eyebrows ...................................................... 1
F. Window ......................................................... 1
G. Machinery Compartment Access Panel ........ 1
H. Serial Plate .................................................... 1
I. Control Panel ................................................ 1
J. Photo Cell ..................................................... 1
K. Gas Burner .................................................... 1
L. Blowers ......................................................... 1
M. Air Fingers ..................................................... 1
III. OVEN SPECIFICATIONS ........................................ 2
A. Dimensions ................................................... 2
B. General Specifications .................................. 2
C. Electrical Specifications for
PS640 Gas Ovens ........................................ 2
D. Gas Orifice and Pressure Specifications
for PS640 Gas Ovens ................................... 2
SECTION 2 – INSTALLATION ........................................... 3
I. BASE PAD KIT ......................................................... 4
II. INSTALLATION KIT ................................................. 5
III. VENTILATION SYSTEM .......................................... 8
A. Requirements ................................................ 8
B. Recommendations ........................................ 8
C. Other Ventilation Concerns ........................... 8
IV. ASSEMBLY .............................................................. 9
A. Base Pad, Legs, Casters .............................. 9
B. Stacking ....................................................... 10
C. Restraint Cable Installation ......................... 10
D. Conveyor Installation .................................. 11
E. Standoff Installation .................................... 11
V. FINAL ASSEMBLY ................................................. 12
VI. ELECTRICAL SUPPLY .......................................... 12
Connection ....................................................... 13
VII. GAS SUPPLY ........................................................ 13
A. Gas Utility Rough-In Recommendations ..... 13
B. Connection .................................................. 14
C. Gas Conversion .......................................... 14
D. Propane Conversion ................................... 14
E. Adjusting the Maximum Pressure Setting ... 14
F. Adjusting the Minimum Pressure Setting .... 15
G. Checkout ..................................................... 15
H. Maintenance ............................................... 15
Page
SECTION 3 – OPERATION .............................................. 14
I. LOCATION AND DESCRIPTION OF CONTROLS 16
II. NORMAL OPERATION, STEP-BY-STEP ................ 17
A. Main Screen ................................................ 17
B. Daily Startup Procedure .............................. 18
C. Daily Shutdown Procedure ......................... 18
III. QUICK REFERENCE: TROUBLESHOOTING ...... 19
IV. SCREEN ALERTS ................................................. 19
SECTION 4 – MAINTENANCE ........................................ 20
I. MAINTENANCE – DAILY ....................................... 20
II. MAINTENANCE – MONTHLY ............................... 21
III. MAINTENANCE – EVERY 3 MONTHS ................. 22
IV. MAINTENANCE – EVERY 6 MONTHS ................ 23
V. KEY SPARE PARTS KIT ....................................... 24
SECTION 5 – ELECTRICAL WIRING DIAGRAM ............ 25
I. WIRING DIAGRAM, 640 GAS OVEN, 208/240V,
50/60 Hz, 1 Ph ....................................................... 25
NOTE
Wiring Diagrams are in Section 5 of this Manual.
The diagram for each oven is also on the lower
inner surface of its Control Console.
iv
SECTION 1 – DESCRIPTION
I. OVEN USES
PS640 Series Ovens can be used to bake and/or cook a wide
variety of food products, such as pizza, pizza –type products,
cookies, sandwiches and others.
II. OVEN COMPONENTS – see Figure 1-1.
A. Conveyor Drive Motor: Moves the conveyor.
B. Crumb Pans: Catch crumbs and other materials that drop
through the conveyor belt. One crumb pan is located at
each end of the conveyor.
C. Conveyor: Moves the food product through the oven.
D. End Plugs: Allow access to the oven’s interior.
E. Eyebrows: Can be adjusted to various heights to prevent
heat loss into the environment.
F. Window: Allows the user to access food products inside
the baking chamber.
G. Machinery Compartment Access Panel: Allows access
to the oven’s interior and control components. No user
serviceable parts are located in the machinery compartment.
H. Serial Plate: Provides specifications for the oven that
affect installation and operation. Refer to Section 2,
lation for details.
I. Control Panel: Location of the operating controls for the
oven. Refer to Section 3,
J. Photo Cell: Turns oven On when beam is interrupted.
Not Shown:
K. Gas Burner (gas ovens): Heat air, which is then projected
to the air fingers by the blowers.
L. Blowers: Project hot air from the burner or heating element
to the air fingers.
M. Air Fingers: Project streams of hot air onto the food
product.
Operation, for details.
Instal-
Figure 1-1. Oven Components
E
D
J
I
G
F
H
A
C
B
1
I. OVEN SPECIFICATIONS
Table 1-1 Dimensions
Overall Height 48-3/16″ (1219mm) 62-3/4″ (1575mm) 78-11/16″ (1981mm)
Overall Depth 60″ (1524mm) 60″ (1524mm) 60″ (1524mm)
Overall Length 76-1/2″ (1930mm) 76-1/2″ (1930mm) 76-1/2″ (1930mm)
Conveyor Width – belt width is 32″ 33-1/2″ (838mm) 33-1/2″ (838mm) 33-1/2″ (838mm)
Recommended Minimum Clearances
Rear of Oven to Wall 3″ (76mm) 3″ (76mm) 3″ (76mm)
Control end of conveyor to Wall 1″ (25.4mm) 1″ (25.4mm) 1″ (25.4mm)
Non-control end of conveyor to Wall) 1″ (25.4mm) 1″ (25.4mm) 1″ (25.4mm)
Table 1-2: General Specifications PS640 GAS
Weight 1150 lbs. (522kg)
Rated Heat Input 120,000 BTU (31,500kcal, 37 kW/hr)
Maximum Operation Temperature 600°F / 315°C
Air Blowers Two Blowers at 1900 RPM
Warmup Time 15 min.
Table 1-3: Electrical specifications for PS640G gas ovens
Main Blower Control Circuit Phase Freq Current Poles Wires
Voltage Voltage Draw
208-240VAC 208-240VAC 1Ph 50/60Hz 11-9.6 Amp 2 Pole 3 Wire (2 hot, 1 gd)
Table 1-4: Gas orifice and pressure specifications for PS640G gas ovens
Gas Main Orifice I.D. Supply (Inlet) Orifice (Manifold) Bypass
Type PS640G Pressure Pressure Pressure
Natural 0.120 6-12″ W.C. (14.9 - 29mbar) 3.5″ W.C. (8.7mbar) 0.2″ W.C. (0.015 mbar)
Propane 1.9mm 11-14″ W.C. (27.4 - 34.9mbar) 10.0″ W.C. (24.9mbar) 0.5″ W.C. (0.12 mbar)
IMPORTANT –
Additional electrical information is provided on the oven’s serial plate, and on the wiring diagram
inside the machinery compartment.
Single Oven Double Oven Triple Oven
or 2 × 15″ (381mm) or 2 × 15″ (381mm) or 2 × 15″ (381mm)
GAS ORIFICE AND PRESSURE SPECIFICATIONS (PER OVEN CAVITY) - CE OVENS
Supply (Inlet) Pressure
Gas Orifice DK,FI NL DE BE,FR FI,DE,NL ES,UK (Manifold) Heat
Main UK,CH,IT,AT, SE,CH,AT,DK, BE,IE,IT,PT, Orifice Rated
Type dia.
G20 0.120″ 20 -- 20 20 -- -- 11.21 22.36
(3.05 mm) mbar mbar mbar mbar kW-hr.
G25 0.120″ -- 25 -- -- -- -- 16.19 22.36
(3.05 mm) mbar mbar kW-hr.
G30 0.075″ -- -- -- -- 29 or 50 28-30, 37 26.2 22.59
(1.9 mm) mbar or 50 mbar mbar kW-hr.
IT,PT,ES,SE,
I
2H
I
2L
I
2E
I
2E+
I
3B/P
I
3+
Pressure Input
NOTE
Wiring Diagrams are contained in Section 5 of this Manual
and are also located inside the oven at the
bottom of the Control Panel.
Additional electrical information is provided on the oven's serial plate.
This Manual Must Be Kept For Future Reference
2
SECTION 2 – INSTALLATION
WARNING – After any conversions, readjustments, or service work on the oven:
• Perform a gas leak test. • Test for proper combustion and gas supply.
• Test for correct air supply, particularly to the • Check that the ventilation system is in operation.
burner blower.
WARNING - Keep the appliance area free and clear of combustibles.
WARNING – The oven must be installed on an even (level) non-flammable flooring and any adjacent walls
must be non-flammable. Recommended minimum clearances are specified in the Description section of
this manual.
WARNING – Do not obstruct the flow of combustion and ventilation air to and from your oven. There must
be no obstructions around or underneath the oven. Constructional changes to the area where the oven
is installed shall not affect the air supply to the oven.
CAUTION: To reduce the risk of fire, the appliance is to be mounted on floors of noncombustible construction with
noncombustible flooring and surface finish and with no combustible material against the underside thereof, or on
noncombustible slabs or arches having no combustible material against the underside thereof, such construction
shall in all cases extend not less than 12 inches (304mm) beyond the equipment on all sides.
CAUTION: For additional installation information, contact your local Authorized Service Agent.
NOTE – There must be adequate clearance between the oven and combustible construction. Clearance must also
be provided for servicing and for proper operation.
NOTE – An electrical wiring diagram for the oven is located inside the machinery compartment.
NOTE: All aspects of the oven installation, including placement, utility connections, and ventilation requirements,
must conform with any applicable local, national, or international codes. These codes supersede the requirements
and guidelines provided in this manual.
NOTE: In the USA, the oven installation must conform to local codes. In the absence of local codes, gas oven
installations must conform with the National Fuel Gas Code, ANSI Z223.1. Gas and electric ovens, when installed,
must be electrically grounded in accordance with local codes, or in the absence of local codes, with the National
Electrical Code (NEC), or ANSI/NFPA70.
NOTE: In Canada, the oven installation must conform with local codes. In the absence of local codes, gas
oven installations must conform with the Natural Gas Installation Code, CAN/CGA-B149.1, or the Propane Gas
Installation Code, CAN/CGA-B149.2, as applicable. Gas and electric ovens, when installed, must be electrically
grounded in accordance with local codes, or in the absence of local codes, with the Canadian Electrical Code
CSA C22.2.
3
PS640 OVEN INSTALLATION
REQUIRED KITS AND EQUIPMENT
PS640 PS640 PS640 PS640
Gas Oven Single Oven DoubleOven TripleOven
Installation Option Base w/ OptionBase w/ OptionBase w/
TYPE OF INSTALLATION Kit 15″ Legs, 6″ Legs, Casters& Top
Casters & Top Casters & Top Kit
Kit Kit
P/N51100 P/N59720 P/N59725 P/N59726
PS640 Single Gas Oven 1 1
PS640 Double Gas Oven 2 1
PS640 Triple Gas Oven 3 1
PARTS LIST FOR SERIES PS640 GAS OVEN
INSTALLATION KIT
P/N 51100
(Two required for double oven)
(Three required for triple oven)
ITEM
NO. QTY PART NO. DESCRIPTION
1 1 22361-0001 FLEXIBLE GAS HOSE
2 1 55028 CONVEYOR END STOP
3 1 55027 CONVEYOR LEFT REAR STOP
4 1 42612 SERVICE AGENCY DIRECTORY
5 1 22500-0080 LABEL, MM
6 1 51054 ASSY, HANDLE & DOOR
Figure 2-1. PS640-Series Gas Oven Installation Parts
1
5
4
4
2
3
6
HARDWARE BAG
5, 6, 7, 10 & 11
2
Figure 2-2. Model PS640 Single Oven
Option Base with Legs and Top
1
8
3
4
PARTS LIST FOR PS640 SERIES SINGLE OVEN OPTION - BASE w/15
P/N 59720
ITEM NO. QTY PART NO. DESCRIPTION
1 1 60287 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″-16 × 1″ HEX SCREW, SST
6 32 21416-0001 3/8″ FLAT WASHER, SS
7 32 21422-0001 3/8″ SPLIT LOCK WASHER, ZP
8 1 22450-0228 RESTRAINT CABLE ASSEMBLY
9 1 59560 TOP COVER
10 2 59677 SCR, MS SL TR HD 10-32 × 2-1/2″
11 2 7A2S15 SCR, MS STR TRSHD 10-32 × 3/4″
9
″″
″ LEGS & TOP
″″
5
HARDWARE BAG
5, 6, 7, 10 & 11
2
Figure 2-3. Model PS640 Double Oven
Option Base with Legs and Top
1
8
3
4
PARTS LIST FOR PS640 SERIES DOUBLE OVEN OPTION - BASE w/6
P/N 59725
ITEM NO. QTY PART NO. DESCRIPTION
1 1 60287 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 3/8″-16 × 13 HEX SCREW, SST
6 32 21416-0001 3/8″ FLAT WASHER, SS
7 32 21422-0001 3/8″ SPLIT LOCK WASHER, ZP
8 1 22450-0228 RESTRAINT CABLE ASSEMBLY
9 1 59560 TOP COVER
10 2 59677 SCR, MS SL TR HD 10-32 × 2-1/2″
11 2 7A2S15 SCR, MS STR TRSHD 10-32 × 3/4″
9
″″
″ LEGS & TOP
″″
6
Figure 2-4. Model PS640 Triple Oven
Option Base with Outriggers and Top
1
HARDWARE BAG
7, 8, 9, 10, 11, 12,
13, 14, & 17
5
6
2
15
3
4
16
PARTS LIST FOR PS640 SERIES TRIPLE OVEN OPTION - BASE w/CASTERS & TOP
P/N 59726
ITEM NO. QTY PART NO. DESCRIPTION
1 1 60287 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 SPACER,QUAD CASTER
7 32 A27727 3/83 -16x1-1/4 HEX BOLT
8 32 A21924 3/83 FLAT WASHER, SS
9 32 21422-0001 3/83 SPLIT LOCK WASHER, ZP
10 16 21172-0004 3/83 -16 NYLON INSULATED LOCKNUT, ZC
11 8 2001048 1/23 -13 x 1-3/8 18-8 HEX CAPSCREW
12 8 A27750 1/23 18-8 FLAT WASHER
13 8 21422-0016 1/23 18-8 LOCK WASHER
14
15 1 22450-0228 RESTRAINT CABLE ASSEMBLY
16 1 59560 TOP COVER
17 2 7A2S15 SCR, MS STR TRSHD 10-32X3/4″
2
59677 SCR, MS SL TR HD 10-32X2-1/2
7
III. VENTILATION SYSTEM
IMPORTANT
Where national or local codes re-
quire the installation of fire sup-
pression equipment or other
supplementary equipment, DO NOT
mount the
equipment directly to the oven.
MOUNTING SUCH EQUIPMENT ON
THE OVEN MAY:
• VOID AGENCY CERTIFICATIONS
• RESTRICT SERVICE ACCESS
• LEAD TO INCREASED SERVICE
EXPENSES FOR THE OWNER
B. Recommendations
NOTE THAT THE HOOD DIMENSIONS SHOWN IN
FIGURE 2-5 ARE
LOCAL, NATIONAL AND INTERNATIONAL CODES
MUST BE FOLLOWED WHEN INSTALLING THE
VENTILATION SYSTEM. ANY APPLICABLE CODES
SUPERSEDE THE RECOMMENDATIONS SHOWN IN
THIS MANUAL.
The rate of air flow exhausted through the ventilation system
may vary depending on the oven configuration and hood
design. Consult the hood manufacturer or ventilation engineer
for these specifications.
To avoid a negative pressure condition in the kitchen area,
return air must be brought back to replenish the air that was
exhausted. A negative pressure in the kitchen can cause heatrelated problems to the oven components as if there were no
ventilation at all. The best method of supplying return air is
through the heating, ventilation and air conditioning (HVAC)
system. Through the HVAC system, the air can be temperature-controlled for summer and winter. Return air can also be
brought in directly from outside the building, but detrimental
effects can result from extreme seasonal hot and cold temperatures from the outdoors.
RECOMMENDATIONS ONLY.
A. Requirements
CAUTION:
A mechanically driven ventilation system is STRONGLY
RECOMMENDED for electric oven installations.
PROPER VENTILATION OF THE OVEN IS THE RESPONSIBILITY OF THE OWNER.
Gas oven installations REQUIRE a mechani-
cally driven ventilation system with electrical
exhaust air sensing control.
Figure 2-5. Ventilation System
18″ (458mm)
minimum
(Typical - both
ends of oven)
2″ (51mm)
minimum
NOTE:
C. Other ventilation concerns
• Special locations, conditions, or problems may require
• Inadequate ventilation can inhibit oven performance.
• It is recommended that the ventilation system and duct
Return air from the mechanically driven system must
not blow at the opening of the baking chamber. Poor
oven baking performance will result.
the services of a ventilation engineer or specialist.
work be checked at prevailing intervals as specified by the
hood manufacturer and/or HVAC engineer or specialist.
8″ (203mm)
minimum
3″ (76mm)
minimum
8
IV. ASSEMBLY
m
•
Figure 2-6. Leg extension and casters installation
A. Top Panel and Base Pad Assembly
1. Install the four leg extensions onto the base pad using
the 3/8″-16 × 1″ screws, 3/8″ flat washers, and
3/8″ lockwashers supplied in the Base Pad Kit. See
Figure 2-6. Check that the finished sides of each leg
extension face OUTWARDS. One rear leg should be
attached using three 3/8″-16 × 1″ screws and the 3/4″
eyebolt, as shown in Figure 2-6. This eyebolt acts as the
anchor point for the restraint cable assembly (see Part C,
Restraint Cable Installation).
2. If your oven is equipped with the lower shelf, position it in
place as shown in Figure 2-6. Check that the lip on the
shelf faces DOWN. Seal joint between leg and shelf with
NSF listed silicone.
3. Install one caster onto each leg extension, as shown in
Figure 2-7. Use the 3/8″-16 × 1″ screws, 3/8″ flat washers, and 3/8″ lockwashers supplied in the Installation Kit.
The locking casters should be installed at the FRONT of
the oven. The non-locking casters should be installed at
the REAR of the oven.
4. Install the lower oven cavity onto the base pad.
See Fig 2-7.
5. For single ovens ONLY:
Install the top panel using the screws included in the base
pad kit, as shown in Figure 2-8. Then, skip ahead to Part
C, Restraint Cable Installation.
For double or triple ovens:
Continue on to Part B, Stacking. Note that the top panel
should NOT be installed for double and triple ovens until
after stacking the oven cavities.
Finished sides of
leg extension face
corner of base
pad
Lower
shelf
Domestic and
standard export
ovens:
Locking casters -
FRONT of oven
Non-locking casters -
REAR of oven
3/8″ flat
washer
3/8″ lock
washer
3/8″-16 × 1″
hex screw
Figure 2-7. Base pad Installation
oven
Botto
cavity
Assembled•
base pad
Figure 2-8. Top panel installation
#10-32 × 2-1/2″
screw length
#10-32 × 3/4″
screw length
Top
panel
9
NOTE:
DO NOT install top panel onto double or triple
ovens until AFTER stacking the oven cavities. See
Part B, Stacking.
B. Stacking
For single ovens, skip ahead to Part C, Restraint Cable
Installation.
IMPORTANT
Middleby Marshall STRONGLY RECOMMENDS that PS640
Gas oven cavities be stacked BY AUTHORIZED PERSONEL.
Contact your Middleby Marshall Authorized Service Agent for
complete stacking instructions.
1. Stack an oven cavity on top of the lower oven. Check
the following:
• All four sides of the lower lip (on the bottom edge
of the oven cavity) overlap the top of the lower oven
• The oven is level
• The oven is firmly seated
See Figure 2-9.
2. For triple ovens, repeat Step 1 to install the top
oven cavity.
3. Install the top panel using the screws included in the base
pad kit, as shown in Figure 2-10.
C. Restraint Cable Installation
Because the oven is equipped with casters, a restraint cable
assembly must be installed to limit the movement of the appliance without depending on the connector and the quick disconnect device or its associated piping. One end of the cable is
anchored to the eyebolt on the rear surface of the oven’s base
pad, while the other is anchored to the wall. See Figure 2-11.
After connecting the restraint cable, move the oven to its final
location. Adjust the bottom (hex) sections of the feet so that
the casters are off the floor. For quad ovens, lock the two
front casters.
Figure 2-10. Top panel installation
#10-32 × 3/4″
screws
#10-32 × 2-1/2″
screws
Top
panel
Figure 2-9. Stacking
Figure 2-11. Installing the Restraint Cable
Restraint cable assembly
3/8″-18 × 1″
eyebolt on
rear leg
extension
10
3/4″ (19mm)
eyebolt
Wall of structure
D. Conveyor Installation
1. Unfold the conveyor as shown in Figure 2-12. Then, begin
to slide the conveyor into the end of the oven. The
conveyor can only be installed from the end of the oven
with the drive motor.
2. Continue moving the conveyor into the oven until the
frame protrudes equally from each end of the oven.
Check that the crumb tray supports located on the underside of the conveyor frame rest firmly against the lower
end plugs, as shown in Figure 2-13.
3. When the conveyor is positioned properly, check for
freedom of movement of the conveyor belt by pulling it for
about 2-3 feet (0.6-1.0m) with your fingers. The drive and
idler shafts must rotate smoothly, and the belt must move
freely without rubbing on the inside of the oven.
4. Check the tension of the conveyor belt as shown in
Figure 2-14. The belt should lift about 1″ (25mm).
DO NOT OVERTIGHTEN THE CONVEYOR BELT
.
Figure 2-13. Conveyor placement
Crumb tray
support
bracket
End plug
NOTE:
If necessary, the belt tension can be adjusted by
turning the conveyor adjustment screws, located at
the idler (non-control) end of the conveyor. See
Figure 2-14.
Figure 2-12. Conveyor installation
Folded
frame
Idler end (with belt tension
adjustment screws)
Conveyor
placed in
oven
Figure 2-14. Conveyor Belt tension
Drive end (with
drive sprocket)
1″ (25mm)
vertical
deflection
Adjustment
screws (2) on
idler end of
conveyor
11
5. If it is necessary to add or remove conveyor links to
achieve the correct tension, OR if it is necessary to
reverse the conveyor belt for correct orientation, the belt
will need to be removed from the conveyor frame. If this
is necessary, perform the following procedure:
• Remove the conveyor assembly from the oven and
place it flat on the floor.
• Remove the master links using long-nose pliers. Then,
roll up the belt along the length of the conveyor frame.
• Add or remove belt links as necessary to achieve the
correct belt tension.
• Replace the belt on the conveyor frame. Check that the
conveyor belt links are oriented as shown in Figure 2-15,
and that the smooth side of the conveyor belt faces UP.
• Connect the inside master links. Check that the links are
oriented as shown in Figure 2-15.
• Connect the outside master links. Note that the outside
master links each have an open hook on one side. This
hook aligns with the hooks along the sides of the other
conveyor links. See Figure 2-15.
• Replace the conveyor into the oven.
Figure 2-15. Conveyor and Master Link orientation
Direction
of travel
Incorrect
master link
position
E. Final Assembly
1. Install the crumb trays underneath the conveyor as shown
in Figure 2-16.
CORRECT
master link
position
Figure 2-16. Crumb Trays
REVERSING THE CONVEYOR BELT
Remove the conveyor from the oven and find the master link
location. Remove master links and remove the belt from the
conveyor frame. Reassemble the belt back onto the frame (in
the reverse direction) and reinstall the master links. Replace the
conveyor assembly in the oven.
RESETTING DIRECTION JUMPER
Locate Jumper P1 on the conveyor control board. Move jumper
from terminals 1 and 2, and replace onto terminals 2 and 3.
CAUTION: Shock hazard in compartments electrical filters
are electrically alive.
SWITCHING PHOTO DETECTOR
CAUTION: Disconnect Power Before Switching Photo eye.
Remove the three screws securing the access door to the unit.
Open the access door and disconnect the connector fitting to
the photo eye assembly. Remove the two screws securing the
photo eye assembly to the control box. Remove the four nuts
securing the photo eye to the housing. Rotate the photo eye 180
degrees and resecure the photo eye with the four nuts.
On the opposite control box, remove the two screws holding the
cover where the photo eye assembly will be positioned. Secure
the photo eye assembly in position with the two screws. Place
the photo eye cover on the opposite control box, where the
photo eye assembly was removed, and secure the two screws.
Secure the access door with the three screws.
Remove the three screws securing the access door on the
opposite side. Open the access door, where the photo eye is
now positioned, and connect the photo eye connector fitting.
Secure the access door with the three screws.
Apply power to the unit. Adjust the photo eye height by loosening the two screws securing the photo eye assembly and sliding
the photo eye assembly either up or down, such that the beam
is approximately 1/4 inch above the belt.
Crumb tray
insertion
CONVEYOR BELT REVERSAL
Conveyor belt reversal consists of three steps:
1. Physically reversing the conveyor belt.
2. Resetting direction jumper on the conveyor control board.
3. Switching the photo detector.
Note:
This is MUCH easier in reduced light.
Replace all covers.
VI. ELECTRICAL SUPPLY
WARNING: Authorized installation personnel normally
accomplish 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 of the oven.
NOTE: The electric supply installation must satisfy the re-
quirements of the appropriate statutory authority such
as the National Electrical Code, CSA C22.2; the Australian Code AG601; or other applicable regulations.
NOTE: The electric supply connection must meet all national
and local electrical code requirements.
Check the oven serial plate before making any electric supply
connections. Electric supply connections must agree with data
12
Electrical Junction Box
(One per oven cavity)
Figure 2-17. Utility Connection Locations for Gas Ovens
Strain-relief
fitting
Gas Inlet
(One per Single, Double,
or Triple Oven)
on the oven serial plate. The location of the serial plate is shown
in Figure 1-1 (in Section 1,
A fused disconnect switch or a main circuit breaker (customer
furnished)
oven cavity. It is recommended that the switch/circuit breaker
have Lockout/Tagout capability.
The supply conductors must be of the size and material
(copper) recommended. Refer to the wiring diagram inside the
machinery compartment of the oven. Electrical specifications
are also listed on the oven’s serial plate and in Table 1-3,
Electrical Specifications (in Section 1, Description).
The oven requires a ground connection to the oven ground
screw. For gas ovens, the screw is located in the electrical
junction box (see Figure 2-14). If necessary, have the electrician supply the ground wire.
MUST be installed in the electric supply line for each
Description).
Do NOT use the wiring conduit or
other piping for ground connections.
Incoming electrical power lines are fed through the strain-relief
fitting, shown in Figure 2-14. The electrical supply connections
are made inside the electrical junction box. The power lines
then connect to the oven circuits through safety switches
located inside the machinery compartment and each blower
motor compartment. These switches interrupt electrical power
to the oven when the Machinery Compartment Access Panel is
opened, OR when the rear panel is removed.
Connection
Refer to the wiring diagram inside the machinery compartment
of the oven to determine the correct connections for the
electrical supply lines. Connect the supply as indicated on the
wiring diagram.
CAUTION: The terms of the oven’s warranty require all
start-ups, conversions and service work to be
performed by a Middleby Marshall Authorized
Service Agent.
VII. GAS SUPPLY
CAUTION: DURING PRESSURE TESTING NOTE ONE OF
THE FOLLOWING:
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 pressure in excess
of ½ psi (3.45 kPa).
2. The oven must be isolated from the gas supply piping system
by closing its individual manual shutoff valve during any
pressure testing of the gas supply piping system at test
pressure equal to or less than ½ psi (3.45 kPa).
3. If incoming pressure is over 14″ W.C. (35mbar),
a separate regulator MUST be installed in the line BEFORE the individual shutoff valve for the oven.
WARNING: To prevent damage to the control valve regu-
lator during initial turn-on of gas, it is
important to open the manual shutoff valve
very slowly.
After the initial gas turn-on, the manual
shutoff valve must remain open except
during pressure testing as outlined in the
above steps or when necessary during
service maintenance.
A. Gas Utility Rough-In Recommendations
The following gas system specifications are STRONGLY
RECOMMENDED. Deviating from these recommendations
may affect the baking performance of the oven.
Gas Meter
• One or two cavities: 750 cfh meter
• Three oven cavities: 1200 cfh meter
Gas Line
• DEDICATED LINE from the gas meter to the oven
•2″ (50.8mm) pipe for natural gas
•2″ (50.8mm) pipe for propane
• Maximum length: 2002 (61m). Each 90°elbow
equals 7″ (2.13m) of pipe.
13
very
B. Connection
Check the oven’s gas supply requirements before making the
gas utility connection. Gas supply requirement are listed on the
oven’s serial plate and in Table 1-4. Gas Orifice and Pressure
Specifications (in Section 1, Description).
Check the serial plate to determine the type of gas (Propane or
Natural) to be used with the oven.
Refer to the instructions in the gas hose package (included
in the Installation Kit) before connecting the gas line. One
gas line connection method is shown in Figure 2-18;
however, compliance with the applicable standards and
regulations is mandatory.
Inlet, regulated, and pilot gas pressure readings can be
taken using a digital tube manometer at the tap location shown
in Figure 2-19. Figure 2-19 shows the burner assembly and
Figure 2-21 shows the gas valve.
NOTE:
The installation must conform with local codes or in the
absence of local codes, with the National Fuel Gas
Code, ANSI Z223.1-latest edition.
Certain safety code requirements exist for the installation of gas
ovens; refer to the beginning of Section 2 for a list of the installation
standards. In addition, because the oven is equipped with casters, 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 U.S.A.), as well as a quick-disconnect device that complies with the Standard for Quick-Disconnect
Devices for Use With Gas Fuel, ANSI Z21.41 (in U.S.A.).
C. Gas Conversion
Where permitted by local and national codes, it is possible to
convert ovens from natural to propane gas, or from propane to
natural gas. Use the appropriate Middleby Gas Conversion Kit
for the specific oven model.
Figure 2-18. Flexible Gas Hose Installation
1/2″ gas
pipe nipple
1/2″ gas line
tee with
pressure tap
Quick-
disconnect
device
3/4″-1/2″
gas pipe
reducer
3/4″ gas
pipe nipple
90°
Elbow
Flexible
Gas Hose
Figure 2-19. Gas Burner Assembly
Gas Burner
To Gas
Supply
Pipe
Full-Flow
Gas
Shutoff
Valve
Individual gas
connection for
each oven
cavity
CAUTION: The terms of the oven’s warranty require all start-
ups, conversions and service work to be performed by a Middleby Authorized Service Agent.
D. PS640 Propane Conversion
Two items have to be changed, to change the oven to LP:
1. Replace main orifices.
2. Adjust main gas regulator per instructions below.
Disconnect the manifold union closest to the main burner, and
remove the manifold assembly (four screws). Slide out the
manifold assembly (leaving the ignition and sense wires connected). Replace the main orifices.
Replace the main orifices on the manifold assemblies with the LP
units, and replace the manifold assembly. Reconnect the union.
E. Adjusting the Maximum Pressure Setting
1. Disconnect pressure feedback connection (if appcable).
2. Connect a suitable pressure gauge to pipe line or to
outlet pressure tap of gas control concerned, to measure burner pressure (measuring point must be as near
to burner as possible).
Manifold Pressure Tap
3. Make sure that the appliance is in operation and the
Moduplus® coil is energized with maximum current.
4. If maximum rate pressure needs adjustment, use an 8 mm
wrench to turn adjustment screw for maximum pressure
setting (clockwise to increase or counter-clockwise to
decrease pressure), until the desired maximum outlet
pressure is obtained.
5. Disconnect electrical connection of the Moduplus®.
6. Check minimum pressure setting and readjust if necessary. (See Adjusting Minimum Pressure Setting for
proper adjusting procedure.)
7. Reconnect pressure feedback connection (if appcable).
8. If minimum and maximum pressures are set, wire the
Moduplus® in circuit.
9. Close pressure tap screw.
14
Gas
Valv e
Main•
Pressure•
Ta p
Figure 2-20. Burner Assembly
Main•
Orifices
Manifold
Assembly
F. Adjusting the Minimum Pressure Setting
1. Disconnect pressure feedback connection (if appcable).
2. Connect a suitable pressure gauge to pipe line or to outlet
pressure tap of gas control concerned, to measure burner
pressure (measuring point must be as near to burner as
possible).
®
3. Disconnect electrical connection of the Moduplus
.
4. Energize operator, set control in operation and wait until
an outlet pressure is recorded on pressure gauge.
5. If minimum rate pressure needs adjustment, use an 8 mm
wrench to turn adjustment screw for minimum pressure
setting (clockwise to increase or counter-clockwise to
decrease pressure), until the desired minimum outlet
pressure is obtained.
6. Check if main burner lights easily and reliable at minimum
pressure.
7. Reconnect pressure feedback connection (if appcable).
8. Close pressure tap screw.
G. Checkout
After any adjustment, set appliance in operation and observe
through a component cycle to ensure that burner system
components function correctly.
H. Maintenance
It is recommended to check yearly the minimum and the
maximum setting and readjust them if necessary.
Figure 2-21. Gas Valve
Adjustment Screw (5 mm)
for minimum pressure
setting
Adjustment Screw
(8 mm) for
maximum
pressure
setting
15
Increase Decrease
A. Main On/Off Button
SECTION 3 - OPERATION
C. Temperature Control Display
E. Message Bar
D. TEMP Set
Left
LOCATION AND DESCRIPTION OF CONTROLS
A. Main On/Off Button
Turns all oven functions on or off. If the oven is below the set
point, it will rise to the set point and turn the conveyor on. If it is
turned off and the oven is above 200° F, the blowers will remain
on until the oven drops below 200° F.
B. Conveyor Time Setting
Adjusts and displays the conveyor bake time. Dual belt ovens
have two displays, single units have one.
B. Conveyor Time Setting
Right
C. Temperature Control/Display
Displays the set point of the oven.
D. TEMP Set
Pressing on the “TEMP” button shows individual displays and
combined adjustments.
E. Message Bar
Indicates various messages pertaining to current oven
conditions.
16
NORMAL OPERATION - STEP-BY-STEP
A. Main Screen
1. When the unit has been “OFF” for more than 1 minute
the controller will display the screen saver, as shown in
Figure 3-1. To start operation, push the “Enter/Reset”
button. The controller will display the “OFF” screen, as
shown in Figure 3-2.
2. Push the “ON/OFF” button to start the oven. The controller will display the screen, as shown in Figure 3-3.
Figure 3-3 Main Screen ON
Figure 3-1 Screen Saver
©2005 Midd leby Corporation,All ri ght sreser ved
Figure 3-2 Main Screen OFF
The Middleby Corporation
450 F
BELT 01 SPEED
OFF
4m. 30s.
The MiddlebyCorporation
1400Toastmaster Drive
El gin, IL 60120
Phone: 847-741-3300
Fax: 847-741-0015
FRONT BELT JAMMED
450 F
BELT 01 SPEED
ON
ON/OFF button
3. To change the temperature, push the “TEMP” button. The
controller will display the screen, shown in
Figure 3-4. To change the temperature, push the “
arrow button. Then push either the “↑” arrow or “↓” arrow
buttons to increase or decrease temperatures respectively. When the proper temperature is entered, push the
“Enter/Reset” button. The controller will now show the
display shown in Figure 3-3.
Figure 3-4 Temperature Screen
4m. 30s.
←←
←”
←←
17
ON
TEMPERATURE SET UP
AC TUA L T E MP
133.8 F
450.0 F
TEMP Set button
4. To change the conveyor belt speed, push the “TIME”
button. The controller will display the screen, shown in
Figure 3-5. To change the minute setting, push the “
arrow button. Then push either the “↑” arrow or “↓” arrow
buttons to increase or decrease the time accordingly. To
change the second setting, push the “→” arrow button.
Then push either the “↑” arrow or “↓” arrow buttons to
increase or decrease the time accordingly. When the
proper times are entered, push the “ENTER/RESET” button. The controller will now show the display shown in
Figure 3-3.
←←
←”
←←
Figure 3-5 Belt Speed Screen
Message Bar
LEFT FOR MINUTES - RIGHT FOR SECONDS
BELT 01 SPEED
4m. 30s.
C. Daily Shutdown Procedure
1. Make certain there are no products left on the conveyor in
the oven.
2. Press the “ON/OFF” button to turn the oven off.
3. Open the window to allow the oven to cool faster.
4. After the oven has cooled and the blowers have turned off, the
circuit breaker/fused disconnect may be turned off.
Quick Reference – Touch Screen Controller
A. Main Screen
1. ON/OFF button - Used to turn oven On and Off.
2. TIME - See Separate Instructions.
3. TEMP - See Separate Instructions.
4. Energy level indicators - Indicators to either side of the
screen indicate the energy input to that side of the oven.
5. Message bar - Indicates various messages pertaining to
current oven conditions.
B. Oven Temperature/Set Point/Indicator Screen
1. Actual temperature - Indicates current average temperature of the right side of the oven.
2. Set point temperature - Pressing on this value allows the
user to adjust the set point of the oven.
3. Exit - Returns to the main screen.
C. Energy Modes
Energy Mode One - This mode is automatic, and starts (bake
time +1 minute) after the last product has entered
the oven. In this mode, the main oven blowers will lower to 1200
RPM, while the oven maintains temperature and belt speed.
ON/OFF button TIME buttonTEMP button
B. Daily Startup Procedure
1. Check that the circuit breaker/fused disconnect is in the On
position. Check that the window is closed. The touch panel
display should be lit.
2. Adjust the conveyor to the desired bake time.
3. Press the temperature button to display the oven setting.
Set temperature as desired.
4. Press the “ON” button to activate the oven. The conveyor
will not run, until the oven temperature has reached the
set points.
18
III. QUICK REFERENCE: TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Oven will not
turn On.
Oven will not
No electrical power • Check that the circuit breaker/fused disconnect is on.
Make sure the emergenct stop button is on.
No gas pressure
• Make sure main gas is on.
heat.
Oven is operating, but
little or no air is coming
from the fingers.
Conveyor will not move.
Burner did not light
Air fingers may be assembled incorrectly after
cleaning.
Oven is not up to operating
temperature.
Conveyor may be jammed.
Startup Sensor faulty or
sensor window dirty.
• Turn oven off, and restart. If it still does not light, call for
service.
• Turn oven off, and allow to cool. Reassemble fingers
correctly.
• Allow oven to preheat.
• Turn oven off, and allow to cool. Check conveyor for
blockage.
• Clean window.
• Sensor requires maintenance, call for service.
IV. SCREEN ALERTS
SYMPTOM PROBLEM SOLUTION
The internal battery needs
lower right hand corner
High Control Compartment
Temperature
Control Over Temp Rear Grills are clogged. • Clean grills.
Front belt jammed Front belt has stopped. • Remove obstruction, and restart oven.
Rear Belt jammed Rear belt has stopped. • Remove obstruction, and restart oven.
High Temp Error Thermocouple or • Call service.
Belt off-Oven not Normal operation until
in temperature Oven reaches operating
Energy Saving Mode 1 Normal operation.
to be replaced to retain energy mode timings.
Clean rear grills. • Failure to do this will eventually shut down the oven due to
PLC malfunction.
temperature.
• A qualified service technician should accomplish this.Battery Symbol in the
excessive temperature.
• If no obstruction, call service.
• If no obstruction, call service.
19
SECTION 4 - MAINTENANCE
WARNING
Before ANY cleaning or servicing of the oven, 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 the electric supply circuit breaker(s)
3. If it is necessary to move a gas oven for cleaning or servicing, disconnect the gas supply before moving the oven.
When all cleaning and servicing is complete:
1. If the oven was moved for servicing, return the oven
to its original location.
2. If the restraint cable was disconnected to clean or
service the oven, reconnect it at this time.
3. Reconnect the gas supply.
4. Reconnect the electrical supply.
Possibility of injury from moving parts and electrical shock exists in this oven. Switch off and lockout/tagout
the electric supply BEFORE beginning to disassemble, clean, or service any oven. Never disassemble or clean
an oven with the BLOWER ( ) switch or any other circuit of the oven switched on.
NEVER use a water hose or pressurized steam-cleaning equipment when cleaning this oven. To avoid saturating the oven
insulation, DO NOT use excessive amounts of water. DO NOT use a caustic oven cleaner, which can damage the bake
chamber surfaces.
and disconnect the electric supply to the oven.
5. Turn on the full-flow gas safety valve. Test the gas
line connections for leaks using approved leak test
substances or thick soap suds.
6. Turn on the electric supply circuit breaker(s).
7. Perform the normal startup procedure.
WARNING
CAUTION
NOTE
ANY replacement parts that require access to the interior of the oven may ONLY be replaced by a Middleby Marshall
Authorized Service Agent. It is also strongly recommended that the 3-Month Maintenance and 6-Month Maintenance
procedures in this section be performed ONLY by a Middleby Marshall Authorized Service Agent.
I. MAINTENANCE - DAILY
A. Check that the oven is cool and the power is discon-
nected, as described in the warning at the beginning of
this Section.
B. Clean ALL of the cooling fan grills and vent openings
with a stiff nylon brush. Refer to Figure 4-1 for the
locations of the grills and vents.
C. Clean the outside of the oven with a soft cloth and mild
detergent.
D. Check that ALL cooling fans are operating properly.
CAUTION: If a cooling fan is not operating correctly, it must
be replaced IMMEDIATELY. Operating the oven
without adequate cooling can seriously damage
the oven's internal components.
E. Clean the conveyor belts with a stiff nylon brush. This
is more easily accomplished by allowing the conveyor to
run while you stand at the exit end of the conveyor.
Then, brush the crumbs off the conveyor as it moves.
F. Remove and clean the crumb trays. If necessary, refer
to Figure 2-16 (in Section 2,
the crumb trays into the oven.
G. Clean the window in place.
Installation) when replacing
Figure 4-1. Cooling Vents and Grills
Vents on
front panel
of oven
Fan grills (2) on rear
of oven and control
compartment
Vent (1) on rear
of machinery
compartment
20
II. MAINTENANCE – MONTHLY
Figure 4-2. Removing Air Fingers and Plates
NOTE:
A. Check that the oven is cool and the power is disconnected,
B. Remove the crumb trays from the oven.
C. Lift the drive end of the conveyor slightly, and push it
D. Slide the conveyor out of the oven, folding it as it is removed.
NOTE:
E. Remove the end plugs from the oven. The end plugs are
F. Slide the air fingers and blank plates out of the oven, as
When removing the conveyor, refer to Figure 2-12 (in
Section 2,
as described in the warning at the beginning of this Section.
forward into the oven. This removes the tension from the
drive chain. Then, remove the drive chain from the conveyor sprocket.
Split belt conveyors can only be removed from the end
of the oven
Single-belt conveyor assemblies may be removed
from either end of the oven. If it is to be removed from
the end of the oven
drive motor sprocket as described in the
Installation instructions (in Section 2, Installation).
shown in Figure 1-1 (in Section 1,
shown in Figure 4-2. AS EACH FINGER OR PLATE IS
REMOVED, WRITE A “LOCATION CODE” ON IT WITH A
MARKER to make sure that it can be reinstalled correctly.
Installation).
with the drive motor.
without drive motor, remove the
Conveyor
Description).
Figure 4-3. Disassembling the Air Fingers
Example of markings:
(Top Row) T1 T2 T3 T4 T5 T6
(Bottom Row) B1 B2 B3 B4 B5 B6
G. Disassemble the air fingers as shown in Figure 4-3. AS EACH
FINGER IS DISASSEMBLED, WRITE THE “LOCATION CODE”
FOR THE FINGER ON ALL THREE OF ITS PIECES. This will
help you in correctly reassembling the air fingers.
CAUTION: Incorrect reassembly of the air fingers will change
the baking properties of the oven.
H. Clean the air finger components and the interior of the
baking chamber using a vacuum cleaner and a damp
cloth. Refer to the boxed warnings at the beginning of this
Section for cleaning precautions.
I. Reassemble the air fingers. Then, replace them in the
oven, using the “location guide” as a guide.
J. Replace the end plugs on the oven.
K. Reassemble the conveyor into the oven. If the drive
sprocket was removed when installing the conveyor,
replace it at this time.
L. Reattach the drive chain.
M. Check the tension of the conveyor belt as shown in Figure
2-14 (in Section 2,
between 3 - 4″ (75-100mm). DO NOT OVERTIGHTEN
THE CONVEYOR BELT. If necessary, the belt tension
can be adjusted by turning the conveyor adjustment
screws, located at the idler (right) end of the conveyor.
N. Replace the crumb trays.
Installation). The belt should lift
21
III. MAINTENANCE – EVERY 3 MONTHS
A. Check that the oven is cool and the power is discon-
nected, as described in the warning at the beginning of
this Section.
B. Vacuum both of the blower mounts, and their surrounding
compartments, using a shop vacuum.
C. Tighten all electrical terminal screws.
D. Split Belt Disassembly and Cleaning
1. Refer to Part D, Conveyor Installation, in the Installation section of this Manual. Then, remove the following
components from the oven:
• Conveyor end stop
• Crumb trays
• Chain cover
• Drive chains
• End plugs
• Conveyor assembly
2. Remove the master links from each conveyor belt.
Then, roll the belts up along the length of the conveyor
to remove them from the frame.
3. Remove the two conveyor adjustment screws from
the idler end of the conveyor frame, as shown in
Figure 4-4.
4. Remove the idler shaft assembly from the conveyor.
5. Pull apart the two sections of the idler shaft.
6. Clean the shafts thoroughly using a rag. Then, lubri-cate
both the extended shaft and the interior of the hollow
shaft using a light food-grade lubricant.
lubricate the shafts using WD40 or a similar product.
This can cause the shafts to wear rapidly.
7. Before reassembling the shafts into the conveyor
frame, check that they are oriented properly.
Figure 4-4. Disassembling the idler shaft
DO NOT
8. Reassemble the idler shaft into the conveyor. Make
sure that the bronze washer is in place between the
two sections of the shaft. See Figure 4-4.
9. Replace the conveyor adjustment screws as shown in
Figure 4-4. To allow the conveyor belt to be reinstalled
later, do not tighten the screws at this time.
10. Loosen the set screw on both of the conveyor drive
sprockets. Then, remove the sprockets from the shaft.
11. Check the conveyor configuration as follows:
High-speed conveyors are equipped with large flange
bearings at both ends of the shaft, as shown in
Figure 4-5. For these conveyors, remove the two
screws that hold each bearing to the conveyor frame.
With the screws removed, lift the end of the shaft at the
front of the oven, and pull the entire assembly free of
the conveyor frame.
Standard conveyors are equipped with bronze bushings mounted on spacers at both ends of the shaft, as
shown in Figure 4-5. For these convey-ors, remove
the two screws that hold the bracket to the conveyor
frame. With the screws removed, lift the end of the
shaft at the front of the oven, and pull the entire
assembly free of the conveyor frame. The brackets
will be removed along with the drive shaft assembly.
12. Disassemble and lubricate the two sections of the
drive shaft as described for the idler shaft, above.
13. Before reassembling the shafts into the conveyor
frame, check that they are oriented properly.
14. Reassemble the drive shaft into the conveyor.
sure that the bronze washer is in place between the
two sections of the shaft. See Figure 4-4.
15. Replace the drive sprockets. Reassemble the belts
and master links onto the conveyor.
16. Reinstall the end plugs and conveyor onto the oven.
17. Reattach the drive chains. Replace the chain cover.
18. Check the tension of the conveyor belt as shown in
Figure 2-14 (in Section 2,
lift about 1″ (25mm). If necessary, adjust the belt
tension by turning the conveyor adjustment screws.
19. Replace all components onto the oven.
Installation). The belt should
Make
22
Figure 4-5. Drive shaft configurations
Figure 4-6. Disassembling the drive shaft
Figure 4-7. Rear panel access
Remove eight (8)
screws to remove
rear panel
Bearings
(2 total)
Grease fitting
(1 per
bearing)
Blower belt
E. Blower Belt
1. Remove the six screws shown in Figure 4-7. Then,
remove the rear panel from the oven.
2. Check the blower belt for the proper 1/4″ (6mm) deflection at the center, and for cracking or excessive wear.
See Figure 4-7. Overtightening the belt will cause premature
bearing failure and possible vibrations. A loose belt may also
cause vibrations.
3. If necessary, adjust the tension of the belt by loosening
the four motor mounting bolts. Reposition the motor as
neccessary until the correct 1/4″ (6mm) deflection is
reached, then tighten the bolts.
Blower motor
Loosen four (4) screws to adjust
motor position and belt tension
IV. MAINTENANCE - EVERY 6 MONTHS
A. Check that the oven is cool and the power is discon-
nected, as described in the warning at the beginning of
this Section.
B. Check for excessive wear on the conveyor drive motor
brushes. The brushes should be replaced if they have
worn to less than 1/4″ (6mm) in length. Be sure to replace
the brushes in exactly the same position.
C. For gas ovens, inspect and clean the burner nozzle and
the spark electrode assembly.
D. Check the conveyor drive shaft bushings and spacers.
Replace the components if they are worn.
23
V. KEY SPARE PARTS – Available separately. See Figure 4-8.
12 345
10
15
16, 17, 18
19
Figure 4-8. Key Spare Parts
KEY SPARE PARTS PS640 GAS (B & W Touchscreen)
ITEM QTY. P/N DESCRIPTION
1 1 60191 Digital Display, Programmed
2 1 58920 Motor, Conveyor Drive
3 1 58679 Conveyor Control Board
4 1 60192 Inverter, Programmed
5 1 M9608 Power Supply
6 1 60196 Kit, Thermocouple
7 1 97525 Fan Cooling Control
8 1 51399 Fan Cooling Rear
9 1 50610 Air Switch
10 1 57288 Motor, Blower
11 1 50239 Ignition Module
12 1 60679 Assy, Valve Gas Modulating
13 1 60671 Board, Signal Cond. 0-15VDC
14 1 33983 High Limit Control Module,240V
15 2 32108 Transformer,240Vp:24Vs
16 1 60193 PLC ModuIe, Programmed
17 1 58668 Thermocouple Module
18 1 58669 Current Module
19 1 60091 PhotoCell
20 2 59132 Relay, DPDT 24V Coil
21 1 59668 Belt, Blower
22 1 48455 Ignitor, Single Rod
23 1 50240 Ignition Cable, 25″
20
21
22
23
24
SECTION 5 - WIRING DIAGRAM
59324 Rev. A6
25
Middleby-Marshall Model Number G208-240 Volt 50/60 Hz, 1 Phase
NOTES27NOTES
26
WARNING
Improper installation, adjustment, alteration, service or maintenance
can cause property damage, injury or death. Read the installation,
operating and maintenance instructions thoroughly before
installing or servicing this equipment.
NOTICE
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.
NOTICE
Using any parts other than genuine Middleby Marshall factory manufactured parts
relieves the manufacturer of all warranty and liability.
NOTICE
Middleby Marshall reserves the right to change specifications at any time.
Middleby is proud to support the Commercial Food Equipment
Service Association (CFESA). We recognize and applaud
CFESA's ongoing efforts to improve the quality of technical
service in the industry.
Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • USA • (847)741-3300 • FAX (847)741-4406
www.middleby.com
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