Middleby Cooking Systems Group PS520E User Manual

installation
& operation
manual

PS520-Series OVENS

Model PS520E

PS520-Series Electric Ovens:English

PS520 Single

PS520 Double

©2006 Middleby Marshall Inc.

PS520 Triple

Part No., 52358

090/6

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 installa-

tion, operating, and maintenance instruc-

tions thoroughly before installing or servic-

ing this equipment.

NOTICE

The warranty is NOT VALID unless the oven is installed, started, and demon-

strated under the supervision of a factory-authorized installer

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.________________________ Serial No._______________ Installation Date __________

MIDDLEBY MARSHALL

No Quibble Limited Warranty

(U.S.A. Only)

Middelby Marshall, Hereinafter referred to as “The Seller”,
warrants equipment manufactures by it to be free from defects
in materials and workmanship for which it is responsible. The
seller’s obligation under thus 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 purchase of (1) 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 no quibble 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 and Hawaii. The
warranty is valid in the 50 Unites 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 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.

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 forgoing 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

©2006 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 - [phone] - Fax: [phone]

iii

Table of Contents

SECTION 1 - DESCRIPTION

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

Series PS520 Electrical Specifications ............................. 2

II. COMPONENT FUNCTION .......................................... 3

A. Conveyor Motor and Conveyor Belt ......................... 3

B. Blower Fan ............................................................... 3

C. Electric Heaters ........................................................ 3

D. Cooling Fan .............................................................. 3

E. Air Fingers and Blank Plates - Figure 4-8 & 4-14 ..... 3

SECTION 2 - INSTALLATION

I. UNLOADING ................................................................. 4

PS520 Oven Installation

Required Kits And Equipment ................................... 5

Oven Dimensions - Single, Double, Triple ................... 6

Utility Rough In Dimensions and Positioning

For PS520 Series Ovens .......................................... 7

Circuit Breaker .............................................................. 7

Electrical Specifications ................................................ 7

Electrical Rating ............................................................ 7

Supply Wire .................................................................. 7

Suggested ..................................................................... 7

II. VENTILATION GUIDELINES ....................................... 7

III. ELECTRICAL CONNECTION INFORMATION FOR

PS520-SERIES OVENS ........................................... 8

IV. ELECTRIC SUPPLY FOR ELECTRIC-HEATED

OVENS ...................................................................... 8

SECTION 3 - OPERATION

I. CONTROL FUNCTIONS ............................................... 9

II. COMPONENT FUNCTIONS ...................................... 10

A. Door Safety Switch ................................................. 10

B. Blower Switch ......................................................... 10

C. Heat Switch ............................................................ 10

D. Temperature Controller .......................................... 10

E. Conveyor ................................................................ 11

Measuring Conveyor Speed ....................................... 11

III. STEP-BY-STEP OPERATION .................................. 12

A. Start-up Procedures ............................................... 12

Daily Start-up .......................................................... 12

Power Failure .......................................................... 12

B. Shutdown Procedure .............................................. 12

IV. NORMAL OPERATION - STEP-BY-STEP ............... 13

A. Daily Start-up Procedure ........................................ 13

B. Daily Shutdown Procedure ..................................... 13

V. QUICK REFERENCE: TROUBLESHOOTING .......... 15

Table of Contents

(continued)

SECTION 4 - MAINTENANCE

I. MAINTENANCE - DAILY ............................................. 16

A. Exterior ................................................................... 17

B. Cooling Fan ............................................................ 17

C. Conveyor Belt ......................................................... 17

D. Crumb Pan ............................................................. 17

II. MAINTENANCE - MONTHLY .................................... 18

A. Removing Conveyor From Oven For Cleaning ...... 18

B. Air Fingers Disassembly For Cleaning ................... 20

C. Reassembly of Air Fingers ..................................... 21

D. Reinstall End Plugs ................................................ 23

E. Conveyor Reassembly Into Oven ........................... 24

F. Checking Conveyor Belt Tension ........................... 24

G. Conveyor Belt Link Removal .................................. 25

H. Attaching Drive Chain ............................................ 26

III. MAINTENANCE - EVERY 3 MONTHS ..................... 27

A. Electrical Terminals ................................................ 27

B. Ventilation ............................................................... 27

IV. MAINTENANCE - EVERY 6 MONTHS ..................... 27

Key Spare Parts Kits ................................................... 28

SECTION 5 - TROUBLESHOOTING CHARTS

Trouble Shooting Charts ............................................. 29

SECTION 6 - ELECTRICAL SCHEMATIC

Wiring Diagram, E208-240V 50/60 Hz 1Ph ................ 30

Wiring Diagram, E380-480V 50/60 Hz 1 Ph ............... 31

Wiring Diagram, E230-240V CE, 1Ph ......................... 32

Wiring Diagram, E380-400V CE, 1Ph ......................... 33

Wiring Diagram, E380-400V CE, 3Ph ......................... 34

iv

SECTION 1

DESCRIPTION

I. MODEL IDENTIFICATION

The Mideleby Marshall PS520-Series may be used
either as a single oven or stacked for use as a double
or triple ovens.

A single PS520-Series Oven (Figure 1-1) is mounted
on a base pad with legs. A double oven (Figure 1-2)
consists of two, stacked, single ovens. A triple oven
(Figure 1-3) consists of three stacked single ovens.
The lower oven is mounted on a base pad.

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

SECTION 1

DESCRIPTION

Figure 1-1. Single PS520 Oven

Figure 1-2. Double PS520 Oven

Figure 1-3. Triple PS520 Oven

1

SECTION 1
DESCRIPTION

PS520 SERIES OVEN SPECIFICATIONS

Conveyor Belt Width 18.00” (457mm)

Heating Zone Length 20.00” (5098mm)

Baking Area Square Feet 2.5 sq ft (.023 sq. m.)

Overall Dimensions

Standard Single Oven w/Legs 42.00” (1067mm) L x

35.21” (894mm) W x

21.72” (786mm) H x

Overall Dimensions

Double Oven 42.00” (1067mm) L x

35.21” (894mm) W x

37.27” (947mm) H x

Overall dimensions

Triple Oven 42.00” (1067mm) L x

35.21” (894mm) W x

52.82” (1342mm) H x

Weight of Single Oven 250 lbs (93.3kg)

Shipping Weight 325 lbs (121.3kg)

Operating Range 8.3 kW/hr

Maximum Operating temperature 5500F (2870C)

Warm-up Time 20 min.

Belt Speed Limits 1-10 minutes

SERIES PS520 ELECTRICAL SPECIFICATIONS

Main Blower & Control Circuit Phase Frequency Amperage Poles Wires

Elements Voltage Voltage Draw

All Models 208-240V 208-240V 1 Ph 50/60 Hz See Below 2 Pole 3 Wire

Heater Amperage

Voltage kW Amp

208 8.3 39.9
230 7.6 33.0
240 8.3 34.6

Non-CE 380V 230-240V 1 Ph 50/60 Hz See Below 3 Pole 4 Wire

Heater Amperage (2 hot, 1 neut, 1 grd)

Voltage kW Amp

380 8.3 21.8

Domestic/Non-CE 480V 208-240V 1 Ph 50/60 Hz See Below 3 Pole 4 Wire

Heater Amperage (2 hot, 1 neut, 1 grd)

Voltage kW Amp

480 8.3 17.3

CE Only 380-400V 230-240V 1 Ph 50/60 Hz See Below 2 Pole 3 Wire

Heater Amperage (2 hot, 1 grd)

Voltage kW Amp

380 8.3 21.8
400 8.3 23.0

3 Ph 50/60 Hz See Below 4 Pole 5 Wire

Heater Amperage (3 hot, 1 neut, 1 grd)

Voltage kW L1 L2 L3 N

380 8.3 21.8 21.8 1.2 1.2
400 9.2 23.0 23.0 1.2 1.2

(2 hot, 1 grd)

NOTE

Wiring Diagrams are contained in Section 6 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

II. COMPONENT FUNCTION

SECTION 1

DESCRIPTION

A. Conveyor Motor and Conveyor Belt

The conveyor belt is driven by a variable-speed electric
motor (figure 1-5) 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 1 minute to 10 minutes; this
is the time that a product can take to pass trough the
oven.

B. Blower Fan

The blower fans are located at the rear of the oven. These
blowers force heated air through the air fingers. The
BLOWER switch must be set to “ON” or “I” for oven warm­up and baking.

C. Electric Heaters

There is one heater element mounted on the inside of
the rear panel. The element is connected to an electrical
control which is energized by the temperature controller.

D. Cooling Fan - See Figure 1-4

Blower Motor

Stand off

Cooling Fan

Figure 1-4 Blower Assembly

The cooling fan is located in the back of the oven. The
cooling fan draws air through its grille, blowing it through
the blower motor compartment and the control
compartments into the oven top and exhausted out the
front louvers.

E. Air Fingers and Blank Plates - See Figure 4-8, 4­14

E1. 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 it’s holes aligned with the holes of the
outer plate.

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

Conveyor Drive Motor

Left Control Box

Figure 1-5 Machinery Compartment
Components

3

SECTION 2
INSTALLATION

SECTION 2

INSTALLATION

NOTE: 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

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

CAUTION

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

CAUTION

Do not obstruct the flow of ventilation air to
and from your oven. Do not obstruct the fan
holes in the rear of the unit.

I. UNLOADING

Your Middleby Marshall PS520-Series Oven is
shipped partially assembled. It will arrive in a carton on
a crate.

Carton size for a PS520-Series Oven is:

44-1/4” (112mm) Long x
37-1/2” (953mm) Wide x
23” (584mm) High x

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.

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.

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

4

PARTS LIST FOR SERIES PS520 ELECTRIC OVEN

INSTALLATION KIT

Single and Double Stack Ovens

P/N 48397

Item

NO. QTY PART NO. DESCRIPTION

1 4 3101908 Leg 4” AD FT
2 2 48392 Insulation Bottom Tray
3 1 48394 Bottom Tray Weldment
4 1 48396 Top cover
5 4 51387 Screw MSSLT Thread 8-32 x 1/2, 18-8
6 1 52358 Installation & Operation Manual - English
6 1 59476 Installation & Operation Manual - French

SECTION 2

INSTALLATION

PARTS LIST FOR SERIES PS520 ELECTRIC OVEN

INSTALLATION KIT

Triple Stack Ovens

P/N 54593

Item

NO. QTY PART NO. DESCRIPTION

1 2 48392 Insulation Bottom Tray
2 1 48394 Bottom Tray Weldment
3 1 48396 Top cover
4 4 51387 Screw MSSLT Thread 8-32 x 1/2, 18-8
5 4 M3828 Pin, Alignment
6 1 52358 Installation & Operation Manual - English
6 1 59476 Installation & Operation Manual - French

5

SECTION 2
INSTALLATION

Figure 2-5. MODEL PS520 SINGLE OVEN DIMENSIONS

1

The Opening Height is Adjustable
from 2-1/4 inch minimum to 3-3/4
inch maximum in 1/2 inch
increments.

Figure 2-6. MODEL PS520 DOUBLE OVEN DIMENSIONS

Figure 2-7. MODEL PS520 TRIPLE OVEN DIMENSIONS

6

UTILITY ROUGH-IN DIMENSIONS AND POSITIONING

FOR PS520 SERIES OVENS

WARNING

DO NOT USE CONDUIT OR GAS LINE FOR
GROUNDING CONNECTION

CAUTION

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

SECTION 2

INSTALLATION

To Oven

ELECTRIC SUPPLY TO BE

PROVIDED BY CUSTOMER

CIRCUIT BREAKER

Separate circuit breaker with lockout/tagout electrical
shutoff for each oven. Wire each oven separately.

50 amp circuit breaker for 208-240V, or 30 Amp circuit
breaker for 380-480V.

ELECTRICAL SPECIFICATIONS
ALL MODELS:

•208V main blower motors and elements, 1 Ph, 39.9

Amp draw, 50/60 Hz, 208V control circuit, 2 pole,
3 wire system per oven (2 hot, 1 grd).

•230V main blower motors and elements, 1 Ph, 33.0
Amp draw, 50/60 Hz, 230V control circuit, 2 pole,
3 wire system per oven (2 hot, 1 grd).

•240V main blower motors and elements, 1 Ph, 34.6
Amp draw, 50/60 Hz, 208-240V control circuit, 2 pole,
3 wire system per oven (2 hot, 1 grd).

Non-CE:

•380V elements, 1 Ph, 21.8 Amp draw, 50/60 Hz, 208-

240V control circuit and main blower motor, 3 pole,
4 wire system per oven (2 hot, 1 neut, 1 grd).

Domestic and Non-CE:

•480V elements, 1 Ph, 17.3 Amp draw, 50/60 Hz, 208-

240V control circuit and main blower motor, 3 pole,
4 wire system per oven (2 hot, 1 neut, 1 grd)

CE Only:

•380V elements, 1 Ph, 21.8 Amp draw, 50/60 Hz, 208-

240V control circuit and main blower motor, 2 pole,
3 wire system per oven (2 hot, 1 grd).

•400V elements, 1 Ph, 23.0 Amp draw, 50/60 Hz, 208­240V control circuit and main blower motor, 2 pole,
3 wire system per oven (2 hot, 1 grd)

•380V elements, 3 Ph, 21.8/21.8/1.2 Amp draw, 50/60
Hz, 5 pole, 4 wire system per oven (3 hot, 1 neut, 1
grd).

•400V elements, 3 Ph, 23.0/23.0/1.2 Amp draw, 50/60
Hz, 5 pole, 4 wire system per oven (3 hot, 1 neut, 1
grd)
Do NOT use conduit for ground.

To Oven

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

Figure 2-9. Typical PS520-Series Oven(s)

Installation

ELECTRICAL RATING

7.6 - 9.2 kW/hr

SUPPLY WIRING

Supply wire size must be in accordance with the National
Electrical Code (current edition) and must be in compliance

with local codes.

SUGGESTED

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

CAUTION

UNIT MUST HAVE AIR VENT PLATES

INSTALLED OR WARRANTY WILL BE VOID.

II. VENTILATION

A mechanically driven ventilation system is required for
the PS520 Series Middleby Marshall conveyorized electric
ovens.

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.

Please Note: There are now two “stand off” “C”
channels that must be installed in the field (See Section
1: Figure 1-4, page 3 for reference)

7

SECTION 2
INSTALLATION

These “C” Channel brackets are installed in the vertical
plane using existing screws to support these ‘C”
Channels using the upper and lower Key Hole openings
in the ‘C’ Channels. The “C” Channels are identical and
once installed will allow ample amounts of air through
the cooling fan mounted on the rear side of the oven by
keeping the oven away from the rear wall.

III. ELECTRICAL CONNECTION INFORMATION

FOR PS520-SERIES OVENS.

WARNING

Authorized supplier personnel normally
accomplish the connection for the ventilation
system, electric supply, as arranged by the
customer. Following these connections, the
factory-authorized installer can perform the
initial start-up of the oven.

Check the oven data plate (Figure 2-10) before making
any electric supply connections. Electric supply
connections must agree with data on the oven data plate.

A fused disconnect switch or a main circuit breaker
(customer supplied) 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 ELECTRICALLY

HEATED OVENS

Power requirements for electrically heated ovens are
usually 208-240VAC, 1-phase, 3 wire (2 ‘hot’, 1 ground),
although ovens built for export can have power
requirements of 380VAC and 480VAC. (These ovens
have a 4-wire or 5-wire system.) A 1.5” (38mm) diameter
cutout/hole in the back of the machinery compartment
provides access for the electrical supply connections on
380V and 480V units. 208V and 240V units have a cord
and plug. Using flexible cable(s) for the electrical power
supply conductors requires a 2” (51mm) strain-relief fitting
(not furnished) to enable safe access to the terminal block
from which oven power is distributed.

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 and material
(copper) recommended to provide the current require;
(refer to the data plate for the ampere specifications).

Typical specifications for each PS520-Series Oven are
208-240V, 1-phase, 3 wire, 8.3kW; this oven requires
50 ampere service. A PS520-Series Double Oven (Figure
1-2) installation would require two 50 ampere service
connections, one for each oven; the 8.3kW power
consumption also doubles for such an installation to

16.6kW.

The 208V, 230V or 240V AC electrically heated oven
uses two legs of the supplied power to provide 208V,
230V or 240V AC power for the oven control circuitry

ELECTRICAL
INLET

Figure 2-10. Typical Electric Oven Data Plate

Figure 2-11. Junction Connection Box

8