Middleby PS540G Operators Manual

MiddlebyMiddleby

Middleby

MiddlebyMiddleby
MarshallMarshall

Marshall

MarshallMarshall

A MIDDLEBY COMPANY

owner's
operating

& installation

manual

PS540-Series Gas Ovens: English

November 12, 2008 Rev.B

®

PS540-Series

Model

PS540G

OVENS

PS540 (Single)

PS540 (Double)

©2003 Middleby Marshall Inc.

PS540 (Triple)

Part No. 50664

Price $30.00

P: 11/08

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
instructions thoroughly before installing or servicing this
equipment.

WARNING

POST, IN A PROMINENT LOCATION, THE EMERGENCY PHONE
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 YOUR LOCAL GAS SUPPLIER. IF
THE SMELL OF GAS IS DETECTED, IMMEDIATELY CALL THE EMERGENCY
PHONE NUMBER OF YOUR LOCAL GAS SUPPLIER. THEY WILL HAVE THE
PERSONNEL AND PROVISIONS AVAILABLE TO CORRECT THE PROBLEM.

NOTICE

The warranty is
demonstrated under the supervision of a factory-authorized installer.

NOT VALID

unless the oven is installed, started, and

NOTICE

Contact your authorized Service Agency to perform maintenance and

repairs. A Service Agency Directory is supplied with your oven.

NOTICE

Using any parts other than genuine Middleby Marshall factory-manufactured
parts relieves the manufacturer of all warranty and liability.

NOTICE

Middleby Marshall (Manufacturer) reserves the right to

change specifications at any time.

KEEP THIS MANUAL IN A VISIBLE LOCATION NEAR THE OVEN

FOR FUTURE REFERENCE.

ii

Model No.
Modéle No.

Serial No.
Serié No.

Installation Date
Date d'installation

MIDDLEBY MARSHALL

NO 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

SECTION 1

I. MODEL IDENTIFICATION .............................................. 1

SERIES PS540 ELECTRICAL SPECIFICATIONS ............. 2

II. PRINCIPLE OF AIR FLOW ............................................. 3

A. Heat Transfer and How It Works .............................. 3

II. PRINCIPLE OF AIR FLOW (Continued) ........................ 4

B. Air Fingers ................................................................. 4

III. COMPONENT FUNCTION ............................................ 5

A. Conveyor Motor and Conveyor Belt ........................ 6

B. Blower Fan ................................................................. 6

C. Gas Burner ................................................................ 6

D. Window ....................................................................... 6

E. Cooling Fan ................................................................ 7

F. Air Fingers and Blank Plates - See Figure 1-9 ......... 8

SECTION 2

I. UNLOADING ................................................................... 9

PS540 OVEN INSTALLATION

REQUIRED KITS AND EQUIPMENT ........................ 10

PARTS LIST FOR SERIES PS540 GAS OVEN

INSTALLATION KIT P/N 50633 ................................ 10

PARTS LIST FOR PS540 SERIES SINGLE OVEN

OPTION - BASE W/15

PARTS LIST FOR PS540 SERIES DOUBLE OVEN

OPTION - BASE W/6

CASTERS & TOP P/N 34833 .................................... 12

PARTS LIST FOR PS540 SERIES TRIPLE OVEN

OPTION - BASE w/OUTRIGGERS & TOP

P/N 34831 ................................................................... 13

RESTRAINT CABLE INSTALLATION .......................... 16

UTILITY ROUGH-IN DIMENSIONS AND POSITIONING

FOR PS540-SERIES OVENS .................................... 17

ELECTRICAL SAFETY SWITCH .................................. 17

ELECTRICAL SPECIFICATIONS ................................. 17

GAS RATING ................................................................ 17

MINIMUM GAS METER RATING .................................. 17

MINIMUM GAS PIPE SIZE ............................................ 17

GAS SAFETY VALVE ................................................... 17

REQUIRED GAS SUPPLY PRESSURE ....................... 17

SUGGESTED ................................................................ 17

User supplied Items ..................................................... 17

II. VENTILATION GUIDELINES ....................................... 18

VENTILATION HOOD ................................................... 18

VENTILATION CAPTURE TEST ................................... 18

III. ELECTRICAL CONNECTION INFORMATION FOR

PS540-SERIES OVENS. ........................................... 19

IV. ELECTRIC SUPPLY FOR GAS-HEATED OVENS ..... 19

V. GAS SUPPLY FOR GAS HEATED OVENS ................. 20

VI. CONVEYOR REAR STOP AND

END STOP INSTALLATION ...................................... 22

SECTION 3 INSTALLATION

I. CONTROL FUNCTIONS ................................................ 23

II. COMPONENT INFORMATION AND LOCATION ......... 24

A. Door Safety Switch .................................................. 24

B. Blower Switch .......................................................... 24

C. Heat Switch .............................................................. 24

D. Temperature Controller .......................................... 24

E. Conveyor ................................................................. 25

MEASURING CONVEYOR SPEED. ............................. 25

III. STEP-BY-STEP OPERATION ..................................... 26

A. Startup Procedures ................................................. 26

″″

″ LEGS & TOP P/N 34832 ..... 11

″″

″″

″ LEGS,

″″

Page

TABLE OF CONTENTS

(Continued)

Page

Daily Startup ................................................................. 26

Power Failure ............................................................... 26

B. Shutdown Procedure ............................................... 26

A.Daily Startup Procedure .......................................... 26

IV. NORMAL OPERATION - STEP-BY-STEP .................. 26

V. QUICK REFERENCE: TROUBLESHOOTING ............. 30

SECTION 4 MAINTENANCE

I. MAINTENANCE - DAILY ........................................... 32

A. Exterior .................................................................... 32

B. Cooling Fan .............................................................. 3 2

C. Conveyor Belt ......................................................... 3 2

D. Crumb Pans ............................................................ 32

E. Window .................................................................... 32

II. MAINTENANCE - MONTHLY ...................................... 33

A. Removing Conveyor From Oven For Cleaning .... 33

B. Air Fingers Disassembly For Cleaning ................. 35

C. Cleaning the Window .............................................. 3 6

D. Reassembly of Air Fingers .................................... 36

E. Reinstall End Plugs ................................................. 39

F. Conveyor Reassembly Into Oven .......................... 40

G. Checking Conveyor Belt Tension ......................... 40

H. Conveyor Belt Link Removal ................................ 41

I. Replacing Conveyor Belt ......................................... 42

J. Attaching Drive Chain ............................................ 42

III. MAINTENANCE - EVERY 3 MONTHS ........................ 43

A. Cleaning the Blower/Fan Motor ............................. 43

B. Electrical Terminals ............................................... 44

C. Ventilation ............................................................... 44

D. Checking the Blower/Fan Belt ............................... 44

E. Blower Fan Shaft Bearing Lubrication .................. 45

F. Split-belt Conveyor Shaft Cleaning ....................... 45

IV. MAINTENANCE - EVERY 6 MONTHS .................... 47

PS540-SERIES GAS OVEN

KEY SPARE PARTS KIT ......................................... 48

SECTION 5 TROUBLESHOOTING

Troubleshooting Charts ..................................................... 49

SECTION 6 - PARTS LIST

OVEN PANELS, WINDOW AND LEGS ............................ 53

CONTROL PANEL ........................................................... 55

BLOWER AND SHROUD ................................................. 57

CONVEYOR ...................................................................... 59

SPLIT BELT CONVEYOR ................................................. 61

GAS BURNER AND PIPING ASSEMBLY ....................... 63

MACHINERY COMPARTMENT ....................................... 65

SECTION 7 ELECTRICAL SCHEMATICS

Wiring Diagram, G208-240 50/60, 1PH 3W PS540 ........ 67

NOTE

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.

iv

SECTION 1

DESCRIPTION

I. MODEL IDENTIFICATION

The Middleby Marshall PS540-Series may be used either
as a single oven or stacked for use as double or triple
ovens. The major difference between the oven models in
this series is the width of the conveyor.

A single PS540-Series Oven (Figure 1-1) is mounted on a
base pad with legs and casters. A double oven (Figure 1-2)
consists of two,
(Figure 1-3) consists of three stacked single ovens. The
lower oven is mounted on a base pad with short legs and
casters.

On a double or triple oven, the ovens operate completely
independent. All ovens use identical controls and compo­nents. One oven can be cleaned or serviced, while the
others are operating.

stacked,

single ovens. A triple oven

SECTION 1

DESCRIPTION

Figure 1-1. Single PS540 Oven

Figure 1-2. Double PS540 Oven

Figure 1-3. Triple PS540 Oven

1

SECTION 1
DESCRIPTION

PS540 SERIES OVEN SPECIFICATIONS

Conveyor Belt Width 32″ (813mm)

Heating Zone Length 40-1/2″ (1028mm)

Baking Area Square Feet 9 sq. ft. (0.84 sq. m.)

Overall Dimension
Standard Single Oven w/Legs 80″ (2032mm) L ×

Overall Dimension
Double Oven 80″ (2032mm) L ×

Overall Dimension
Triple Oven 80″ (2032mm) L x

Weight of Single Oven 925 lb (419kg)

Shipping Weight 1,100 lb (498.3kg)

Shipping Cube Approx. 132 ft3 (3.74 m3)

Operating Range 110,000 BTU/hr

Maximum Operating Temperature 550°F (287°C)

Warm-up Time 10 min.

Gas Oven Inlet Line Size 3/4″ (19mm) ID for each oven

Minimum Gas Meter Rating 450 cu.ft./hr. (12.74m3h) for 1 to 2 ovens

Minimum Gas Pipe Size
Natural (must be dedicated line) 2″ (51mm) ID for 1, 2, or 3 ovens
Propane (must be dedicated line) 2″ (51mm) ID for 1, 2, or 3 ovens

Gas Pressure
Natural 6″ to 12″ Water Column (13.8 to 29.9 mbar)
Propane 11.5″ to 12″ Water Column (28.7 to 29.9 mbar)

Gas Valve 0.75″ (19mm) ID full-flow, gas, shutoff valve installed in oven inlet gas line.

Recirculating Air Fan One fan at 2300 RPM

Air Velocity 3000 fpm (1524 cm/sec) (Average)

Bake Time 3 min. 0 sec. Bake Time minimum

Inlet

1.13 kPa

2.75 kPa

Add 180 cu.ft./hr (5.1m3h) for each additional oven

A separate connection and valve must be provided for each oven.

61-5/16″ (1557mm) W ×

47-5/16″ (1202mm) H ×

61-5/16″ (1557mm) W ×

60-15/16″ (1548mm) H x

61-5/16″ (1557mm) W ×

77-1/2″ (1969mm) H ×

(116.0 mJ/h)

(27,720 kcal)

(32.2 kW/hr)

Test Power

0.87 kPa

2.39 kPa

30 min. 0 sec. Bake Time maximum

SERIES PS540 ELECTRICAL SPECIFICATIONS

Main Blower & Control Circuit Phase Frequency Amperage Poles Wires

Elements Voltage Voltage Draw

208-240V 208-240V 1 Ph 50/60 Hz 4.1 Amp 3 Pole 3 Wire

(2 hot, 1 grd)

NOTE

Wiring Diagrams are contained in Section 7 of this Manual

and are also located inside the oven at the

bottom of the Control Panel

This Manual Must Be Kept For Future Reference

2

SECTION 1

DESCRIPTION

II. PRINCIPLE OF AIR FLOW

The fan-style blower draws air into the oven plenum where
it is heated. The blower then pushes the hot air through the
air fingers into the baking chamber. Each air finger
contains an inner plate and outer plate that form the hot air
into jets, distributing it across a conveyor belt on which the
food product rides. Air is then pulled back into the blower
and the process continues. The curving, black arrows of
Figure 1-4 show this air flow.

A. Heat Transfer and How It Works

1. Heat constantly moves from a warm object to a cold
object. Heat moves using three different paths: Conduc­tion; Radiation; and Convection.

Conduction:

tact. The pizza dough in contact with the pan is a good
example of conduction.

Radiation:

Dark objects absorb heat whereas light or shiny objects

This path utilizes surface-to-surface con-

This path has to do with objects radiating heat.

Upper Air Fingers

reflect more heat. This is the reason that the inside of a
PS540-Series Oven is light in color: To reflect more heat
back onto the food product.

Convection:

air. It explains why hot air rises and cooler air replaces hot
air. An industrial application of this principle is to incorpo­rate a fan to force the hot air movement, which in turn
increases the heat transfer to the food product.

Each PS540-Series Oven has a large fan-style blower to
move the hot air through the air fingers and onto the
product to cook/bake the food product most efficiently.

2. Temperature is the intensity of heat at the point where
it is sensed. As discussed above, heat flows by conduc­tion, radiation and convection. The speed at which the heat
flows is determined by the temperature difference between
the oven and the food product. The larger the difference,
the faster the heat flows to the item that is being baked.

This path has to do with moving a volume of

Conveyor Belt(s)

Window

Lower Air Fingers

Figure 1-4. PS540-Series Oven Air Flow

3

SECTION 1
DESCRIPTION

II. PRINCIPLE OF AIR FLOW (Continued)

B. Air Fingers

The PS540-Series Ovens are conveyorized ovens that
employ vertical jets of hot air streaming from air fingers
(Figure 1-5) to give uniform, intense heating. The vertical
streams of hot air provide an exceptional heat transfer rate
and generally bake faster and at lower temperatures than
convection hot air or infrared heating ovens.

A PS540-Series Oven can accommodate up to four
bottom air fingers and four top air fingers. Some PS540-

Manifold

Air Flow
From Plenum

High Velocity
Columns of Air
on Food Product

Series ovens used to bake pizza have four bottom fingers
and two top fingers. For special product baking require­ments, a number of other styles of fingers and finger
arrangements are available from the factory.

NOTE:

Some customers have a predetermined finger
arrangement. If you have any questions pertaining to the
finger arrangement, please call the factory.

Manifold Baffle

Outer Plate

Inner Plate

Air Flow
From Plenum

Manifold Baffle

Inner Plate

Outer Plate

Manifold

Figure 1-5. Air Fingers, Showing High-Velocity Columns of Air Formed During Passage Through

the Inner Plate and Outer Plate to Heat the Food Product.

4

III. COMPONENT FUNCTION (Figure 1-6)

SECTION 1

DESCRIPTION

Figure 1-6. PS540-Series Oven Components Locations

5

SECTION 1
DESCRIPTION

III. COMPONENT FUNCTION

A. Conveyor Motor and Conveyor Belt

The conveyor belt is driven by a variable-speed electric
motor (Figure 1-7) operating through a gear reducer. The
motor speed is controlled by a digital control. The stain­less-steel wire belt can travel in either direction at variable
rates ranging from 3 minutes to 30 minutes; this is the time
that a product can take to pass through the oven.

B. Blower Fan

The blower fan is located at the rear of the oven. This
blower forces heated air through the air fingers. The
BLOWER switch must be set to “ON” or “I” for oven
warmup and baking.

C. Gas Burner

Turning the HEAT switch to “1” activates the oven purge
circuit. After approximately 30 seconds, the solid-state
ignition control lights a pilot burner by an electric spark.
This system permits the main gas valve to open
the lighting of the pilot burner is detected by the flame
sensor.

If the pilot flame does not light or a loss of flame occurs,
the main gas valve closes.

The main burner gas is extinguished when the HEAT
switch is set to “OFF” or “O”.

D. Window

A window on the front of the oven permits viewing the items
being baked and provides access to the oven for items that
do not require full baking time, such as sandwiches,
cookies, small items, or cheese-melting processes.

only after

Left Control Box

Figure 1-7. Machinery Compartment Components

Right Control Box

6

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.

SECTION 1

DESCRIPTION

Figure 1-8. Cooling Fan

Cooling Fan Grille

7

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.

2. Inner Plate -The perforated Inner Plate is vital in forming
the unique air jets. It must be assembled into the manifold
with its holes aligned with the holes of the outer plate.

3. Manifold - The Manifold is the assembly which slides
on tracks into the oven plenum.

Half Blank Plate

Outer Plate

F2. Blank Plates

1. Blank Plates- The Blank Plates are available to install
on the plenum where an air finger is not required.

Blank Plate

Inner Plate

Finger
Manifold
Assembly

Baffle

Figure 1-9. Blank Plates (two sizes) and an Air Finger.

8

SECTION 2

INSTALLATION

SECTION 2

INSTALLATION

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 Z223.1 latest edition. The
oven, 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, or in the absence of local codes, with the
Natural Gas Installation Code, CAN/CGA-B149.1, or the
Propane Gas Installation Code, CAN/CGA-B149.2, as
applicable. The oven, 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, as applicable.

NOTE: For Australian installation, the oven must be
installed only by an authorised person in accordance with
AS5601, local authority, gas, electricity, any applicable
statutory regulations and manufacturer requirements.

NOTE

There must be adequate clearance between
the oven and any adjacent combustible con­struction. Clearance must also be provided
for servicing and for operation.

I. UNLOADING

Your Middleby Marshall PS540-Series Oven is shipped
partially assembled. It will arrive in a carton on a crate.

Carton size for a PS540-Series Oven is:

84″ (2134mm) Long ×

58″ (1473mm) Wide ×

44″ (1118mm) High ×

The crate and carton must be examined before signing the
Bill of Lading. Report any visible damage to the transport
company, and check for the proper number of crates. If
apparent damage is found, make arrangements to file a
claim against the carrier. Surface Interstate Commerce
Regulations (U.S.A.) require that the claim must be
initiated by the consignee within 10 days from the date that
the shipment is received.

A Pre-installation Procedures Manual (MM P/N 88910-0009)
is attached to the exterior wall of the carton. This manual
contains detailed instructions on unpacking and moving the
oven(s) to the operating site. When the transport company
notifies you of an impending delivery, arrange to have a forklift
at your facility to unload the carton(s).

Instructions for stacking the ovens is continued in a
separate manual used by Middleby Marshall Authorized
Installers.

CAUTION

It is required that the oven be placed under a
ventilation hood for adequate air supply and
ventilation.

CAUTION

Do not obstruct the flow of combustion and
ventilation air to and from your oven. Do not
obstruct the ventilation holes in the Control Panel.

CAUTION

On ovens with the Machinery Drive Compartment
located at the right end, a minimum clearance of 0″
to a left side wall, 18″ to a right side wall and 6″ from
a back wall to air openings at the rear of the oven
must be maintained. On ovens with the machinery/
drive compartment located at the left end, a mini­mum clearance of 0″ to a right side wall, 18″ to a left
side wall and 6″ from a back wall to air openings at
the rear of the oven must be maintained.

For servicing and cleaning, a minimum of 18″
clearance from all walls is recommended.

If you have a door wider than the carton, simply move the
carton into your facility and arrange an appointment with
your Middleby Marshall Authorized Installer.

If your door is narrower than the carton, then the oven will
have to be unpacked. Follow the directions shown in the
Pre-Installation Procedures Manual.

9

SECTION 2
INSTALLATION

PS540 OVEN INSTALLATION

REQUIRED KITS AND EQUIPMENT

TYPE PS540 PS540 Single PS540 Double PS540 Double PS540 Triple
OF Gas Oven Oven Option Oven Option Oven Option Oven Option
INSTALLATION Installation Base w/15″

Kit P/N Casters & Top Casters & Top & Top & Top

50663 Kit P/N Kit P/N Kit P/N Kit P/N

PS540 Single Gas Oven 1 1

PS540 Double Gas Oven 2 1 1

PS540 Triple Gas Oven 3 1

Legs, Base w/6″

34832 34833 34831 51139

Legs, Base w/Casters Base w/Casters

PARTS LIST FOR SERIES PS540 GAS OVEN

INSTALLATION KIT

P/N 50633

(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 35000-1103 CONVEYOR END STOP

3 1 35900-0148 CONVEYOR LEFT REAR STOP

4 1 50664 SERIES PS540 OWNER/OPERATOR MANUAL

5 1 1002040 SERVICE AGENCY DIRECTORY

6 1 33900-0032 CONVEYOR WIRE BELT

1

4

Figure 2-1. PS540-Series Gas Oven

Installation Parts

10

6

2

3

5

SECTION 2

INSTALLATION

Figure 2-2. Model PS540 Single Oven

Option Base with Legs and Top

PARTS LIST FOR PS540 SERIES SINGLE OVEN OPTION - BASE w/15

P/N 34832

ITEM

NO. QTY PART NO. DESCRIPTION

1 1 37900-0025 COMPLETE BASE WELDMENT
2 4 37900-0024 TOP PLATE, LEG WELDMENT
3 2 22290-0009 SWIVEL CASTER W/BRAKE FLAT PLATE
4 2 22290-0010 SWIVEL CASTER FLAT PLATE
5 32 220373 3/8″-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 4 21256-0008 SCREWS FOR TOP 10-32 × 3/8″ 18-8, SL TRUS S
9 1 22450-0228 RESTRAINT CABLE ASSEMBLY

10 1 33486 TOP COVER 304 PANEL

11

″″

″ LEGS & TOP

″″

SECTION 2
INSTALLATION

Figure 2-3. Model PS540 Double Oven

Option Base with Legs and Top

PARTS LIST FOR PS540 SERIES DOUBLE OVEN OPTION - BASE w/6

P/N 34833

ITEM

NO. QTY PART NO. DESCRIPTION

1 1 37900-0025 COMPLETE BASE WELDMENT
2 4 37900-0102 TOP PLATE, LEG WELDMENT
3 2 22290-0009 SWIVEL CASTER W/BRAKE FLAT PLATE
4 2 22290-0010 SWIVEL CASTER FLAT PLATE
5 32 220373 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 4 21256-0008 SCREWS FOR TOP 10-32 × 3/8″ 18-8, SL TRUS S
9 1 22450-0228 RESTRAINT CABLE ASSEMBLY

10 1 33486 TOP COVER 304 PANEL

12

″″

″ LEGS, CASTERS & TOP

″″

SECTION 2

INSTALLATION

Figure 2-4. Model PS540 Triple Oven

Option Base with Outriggers and Top

PARTS LIST FOR PS540 SERIES TRIPLE OVEN OPTION - BASE w/CASTERS & TOP

P/N 51139

ITEM

NO. QTY PART NO. DESCRIPTION

1 1 54606 COMPLETE BASE WELDMENT
2 4 45209 QUAD OUTRIGGER WELDMENT
3 2 22290-0009 SWIVEL CASTER, W/BRAKE FLAT PLATE
4 2 22290-0010 SWIVEL CASTER, FLAT PLATE
5 4 45206 INSERT,QUAD ADJUSTMENT FOOT
6 4 45205 SPACER,QUAD CASTER
7 32 220373 3/8″-16 × 1″ HEX BOLT, SST
8 32 21416-0001 3/8″ FLAT WASHER, SS

9 32 21422-0001 3/8″ SPLIT LOCK WASHER, ZP
10 16 21172-0004 3/8″-16 NYLON INSULATED LOCKNUT, ZC
11 8 21216-0018 1/2″-13 × 1-1/4″ 18-8 HEX CAPSCREW
12 8 21416-0003 1/2″ 18-8 FLAT WASHER
13 8 21426-0004 1/2″ 18-8 LOCK WASHER
14 4 21256-0008 SCREWS FOR TOP 10-32 × 3/8″ 18-8, SL TRUS S
15 1 22450-0228 RESTRAINT CABLE ASSEMBLY
16 1 33486 TOP COVER 304 PANEL

13

SECTION 2
INSTALLATION

Figure 2-5. MODEL PS540 SINGLE OVEN DIMENSIONS

GAS INLET

3

1

3

3

2

ELECTRICAL JUNCTION BOX

RECOMMENDED MINIMUM CLEARANCES:

3

Rear of Oven to Wall - 6″ (150mm)
Non-control End of Oven to Wall - 0″
Control End of Oven to Wall - 0″

2

1

14

Figure 2-6. MODEL PS540 DOUBLE OVEN DIMENSIONS

GAS INLET

1

SECTION 2

INSTALLATION

3

3

3

2

ELECTRICAL JUNCTION BOX

RECOMMENDED MINIMUM CLEARANCES:

3

Rear of Oven to Wall - 6″ (150mm)
Non-control End of Oven to Wall - 0″
Control End of Oven to Wall - 0″

2

1

15

SECTION 2
INSTALLATION

Figure 2-7. MODEL TRIPLE OVEN DIMENSIONS

GAS INLET

1

3

3

3

2

ELECTRICAL JUNCTION BOX

RECOMMENDED MINIMUM CLEARANCES:

3

Rear of Oven to Wall - 6″ (150mm)
Non-control End of Oven to Wall - 0″
Control End of Oven to Wall - 0″

2

1

RESTRAINT CABLE INSTALLATION

Install the restraint cable assembly on the oven, as shown
in Figure 2-6.

Figure 2-8. Restraint Cable Assembly Installation

16

UTILITY ROUGH-IN DIMENSIONS AND POSITIONING

24"

610mm

6

O

N

O

F

F

13-1/2"
343mm

2

3

2

6

O

N

O

FF

24"

610mm

2

3

2

27"

686mm

4

5

1

Suggested dimensions are shown; utility code
requirements supersede any factors shown.

FOR PS540-SERIES OVENS

WARNING

DO NOT USE CONDUIT OR GAS LINE
FOR GROUND CONNECTION.

CAUTION

IT IS REQUIRED THAT THE OVEN BE
PLACED UNDER A VENTILATION
HOOD FOR ADEQUATE AIR SUPPLY
AND VENTILATION.

ELECTRIC AND GAS SUPPLY TO BE

PROVIDED BY CUSTOMER

SECTION 2

INSTALLATION

ELECTRICAL SAFETY SWITCH

15 Amp circuit breaker / fused disconnect switch with
lockout/tagout electrical shutoff for each oven. Wire

each oven separately.

ELECTRICAL SPECIFICATIONS

DOMESTIC or EXPORT: 208-240V blower motor,

1 phase, 4.1 Amp draw, 50/60 Hz, 208-240V control
circuit, 2 poles, 3-wire system per oven (2 hot, 1 grd).

Do

NOT

use conduit for ground.

GAS RATING

Model PS540 is 110,000 BTU/hour, 116.0 mJ/h (27,720 kcal),

32.2 kW/hr.

MINIMUM GAS METER RATING

450 ft3/hour (12.6m3/h) for 1 or 2 ovens;

Add 180 cu. ft./hr (5.1 m3/h) for each additional oven.

Minimum rating does
consideration. Gas consumption varies at each site. Total
BTU/hr (kcal/hr) must be calculated during high flame
operation for each appliance to determine if the meter
needs to be larger.

MINIMUM GAS PIPE SIZE

Natural: 2″ (51mm) ID for 1, 2, or 3 ovens with runs up

to 200 ft. (61m).

Must be a dedicated line.

Runs over 200 ft, (61m) consult factory.

Propane: 2 ″ (51mm) ID for 1, 2, or 3 ovens with runs up

to 200 ft. (61m).

not

take other gas appliances into

Must be a dedicated line.

Runs over 200 ft, (61m) consult factory.

Figure 2-9. Typical PS540-Series Oven(s)

Installation

GAS SAFETY VALVE

A 3/4″ (19mm) ID (inner diameter) full-flow, gas shutoff
valve. A separate connection and valve must be provided
for each oven, as shown in Figure 2-9.

REQUIRED GAS SUPPLY PRESSURE

Natural: 6″ to 12″ water column (13.8 to 29.9 mbar)

Propane: 11.5″ to 12″ water column (28.7 to 29.9 mbar)

SUGGESTED

If space permits, electric and gas service should be
located near the control console end of the oven(s) to allow
convenient access to safety switches and valves.

USER SUPPLIED ITEMS (Figure 2-9)

ITEM DESCRIPTION

12″ (51mm) × 2″ (51mm) × 3/4″ (19mm) TEE
2 3/4″ (19mm) × 3″ (76mm) NIPPLE
3 3/4″ (19mm) FULL FLOW GAS SHUTOFF VALVE
42″ (51mm) × 3/4″ (19mm) 90° REDUCER ELBOW
52″ (51mm) ID GAS SUPPLY PIPE LINE - NATURAL GAS
6 15 AMP TOGGLE SWITCH - 2 POLE for GAS

17

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 out­lined below.

Local codes and conditions vary greatly from one area to
another and must be complied with. Following are the
suggested requirements for good ventilation. Please re­member these are recommendations or guidelines, you
may have a special condition or problem that will require
the services of a ventilation engineer or specialist. Proper
ventilation is the oven owner’s responsibility. Improper
ventilation can inhibit oven performance. It is recom­mended that the ventilation and duct work be checked out
every three months. Grease filters in the intake of the hood
may be required by local codes.

VENTILATION HOOD

The rate of air flow exhausted through the ventilation
system is generally between 1400 and 2500 cu. ft./min. (40
and 70 m3/min), but may vary depending on the oven
configuration and hood design. 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 heat related
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
system. Through they system, the air can be temperature
controlled for summer and winter. Return air can be
brought in directly from outside the building, but detrimen­tal affects can result from either extreme seasonal hot and
cold temperature from the outdoors.

VENTILATION CAPTURE TEST

It is recommended that a 30 second smoke candle test be
performed on your ventilation hood system. Follow the
steps below to complete the ventilation smoke test.

All tests are to be done on single ovens or lower units of
a double or triple oven. We recommend you wear
protective gloves when performing this test. At no time
should food be present when the smoke test is being
conducted. Also check that no fire suppression system
will be activated by the smoke.

1. Turn ventilation system on.

2. Turn oven(s) on and allow to heat up to customers
normal operating temperature, or a minimum of
480°F (248°C).

3. Turn conveyor off. Place a 30 second smoke candle in
a pie or cake pan which is no higher than 3″ (76mm).

4. Open the front oven window. Next, light the smoke
candle in the pan and then slide the pan into the center of
the bake chamber on the conveyor belt and close the
window.

5. The ventilation hood should capture 90% to 100% of the
smoke produced by the candle.

NOTE: Return air from fan driven system within the hood
must not blow at opening of bake chamber or poor oven
baking performance will result.

2″ (51mm)

minimum.

To allow

stacking of

ovens.

18″
(458mm)
minimum

21-1/2″
(546mm)
minimum

Figure 2-10. Vent Hood

8″ (203mm)

minimum

18

1″ (25mm)

minimum

SECTION 2

INSTALLATION

III. ELECTRICAL CONNECTION

INFORMATION FOR PS540-SERIES
OVENS.

WARNING

Authorized supplier 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.

Check the oven data plate (Figure 2-11) before making any
electric supply connections. Electric supply connections
must agree with data on the oven data plate.

NOTE: The electric supply installation must satisfy the
requirements of the appropriate statutory authority, such
as the National Electrical Code (NEC), ANSI/NFPA70,
(U.S.A.); the Canadian Electrical Code, CSA C22.2; the
Australian Code AG601; or other applicable regulations.

A fused disconnect switch or a main circuit breaker
(customer furnished) MUST be installed in the electric
supply line for each oven; it is recommended that this
switch/ circuit breaker have lockout/tagout capability. The
electric supply connection must meet all national and local
electrical code requirements. Copper is the recommended
material for the electrical supply conductors.

IV. ELECTRIC SUPPLY FOR GAS-

HEATED OVENS

Supply voltages for all gas ovens (except one 200 - 220V
oven for export) can range from 208 to 240VAC, 1 phase.
Ampere requirements for each oven can be handled via a
fused disconnect switch or main circuit breaker.

NOTE: The electric supply installation must satisfy the
requirements of the appropriate statutory authority, such
as the National Electrical Code (NEC), ANSI/NFPA70,

(U.S.A.); the Canadian Electrical Code, CSA C22.2; the
Australian Code AG601; or other applicable regulations.

The supply conductors must be of the size (#14 AWG,
copper) recommended. (Refer to the wiring diagrams of
Section 7.) All gas oven electric supply connections are
made via the electrical junction box on the rear of the oven
(Figure 2-12). The power lines then connect through an
oven safety switch (on the control console door frame) to
the oven circuits. Opening the door interrupts electric
power to the oven.

CAUTION

Before connecting incoming power to the oven,
measure the voltage of each input leg to
neutral. The expected voltage is approximately
120 volts. Any voltage reading exceeding 130
volts indicates that the supply has a ‘high’ leg.
CONNECTING A ‘HIGH’ LEG TO THE OVEN
VOIDS ALL OVEN WARRANTIES. Connecting
a ‘high’ leg to the black lead of the oven can
severely damage the oven’s electrical and
electronic components.

CAUTION

DO NOT CONNECT BLACK

WIRE TO HIGH LEG.

VOLTAGE OF THE BLACK AND

WHITE WIRES MUST BE NO

HIGHER THAN 130 VAC

Contact an electrician or the electric power supply com­pany to remove the ‘high’ leg from the electric supply
line(s) to the oven.

In the junction box on the rear of the oven, connect one
208 - 240V supply line to the black wire and the other
208 - 240V supply line to the red wire. Connect the
supply neutral line to the white wire. Connect the
electric supply ground wire to the oven ground screw
located in the main junction box. If necessary, have
the electrician supply the ground wire.

wiring conduit or other piping for ground connections!

Do NOT use the

Figure 2-11. Typical Gas Oven Data Plate

19