Karcher PS640G User Manual

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 • [phone] • FAX [phone]

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 • [phone] • FAX [phone]

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. • [phone] • FAX: [phone]

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