Middleby Cooking Systems Group PS870 User Manual

PS870 Series
Gas
Domestic
ENGLISH

P/N 59157

August 4, 2006

PS870 Series Gas Ovens

Model:

• PS870G Gas

Combinations:

• Single Oven

• Double Oven (Two-Stack)

• Triple Oven (Three-Stack)

OWNER'S OPERATING AND
INSTALLATION MANUAL

for domestic and standard export ovens

©2006 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]

2

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

ranty

.

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 war-

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]

3

Table of Contents

Page

SECTION 1

DESCRIPTION .................................................................... 5

I. OVEN USES .................................................................... 5

II. OVEN COMPONENTS .................................................... 5

A. Conveyor Motor Drive .............................................. 5

B. Crumb Pans ............................................................... 5

C. Conveyor End Stop and Rear Stop .......................... 5

D. Conveyor End Stop and Rear Stop .......................... 5

E. Conveyor .................................................................... 5

F. End Plugs .................................................................... 5

G. Eyebrows ................................................................... 5

H. Window ....................................................................... 5

I. Machinery Compartment Access Panel ................... 5

J. Serial Plate ................................................................. 5

K. Control Panel ............................................................. 5

L. Gas Burner ................................................................. 5

M. Blowers ...................................................................... 5

N. Air Fingers ................................................................. 5

III. OVEN SPECIFICATIONS ................................................. 5

A. Dimensions ................................................................ 5

B. General Specifications ............................................. 5

C. Electrical Specifications for PS870 Gas Ovens ..... 6

D. Gas Orifice and Pressure Specifications

for PS870 Gas Ovens .............................................. 6

SECTION 2

INSTALLATION .................................................................. 6

I. BASE PAD KIT ............................................................... 7

II. INSTALLATION KIT ........................................................ 8

III.VENTILATION SYSTEM ................................................. 8

A. Requirements ............................................................ 8

B. Recommendations .................................................... 8

C. Other Ventilation Concerns ...................................... 8

Page

IV. ASSEMBLY ...................................................................... 9

A. Base Pad, Legs, Casters, and Stacking .................. 9

B. Restraint Cable Installation ...................................... 9

C. Conveyor Installation ................................................ 9

D. Standoff Installation ................................................ 1 0

V. FINAL ASSEMBLY ....................................................... 11

VI. ELECTRICAL SUPPLY ............................................... 11

Connection .................................................................. 1 2

VII. GAS SUPPLY ............................................................. 1 2

A. Gas Utility Rough-In Recommendations ............... 12

B. Connection ............................................................... 1 3

C. Gas Conversion ....................................................... 13

D. Propane Conversion ............................................... 13

SECTION 3

OPERATION ........................................................................ 14

I. LOCATION AND DESCRIPTION OF CONTROLS ....... 14

II. NORMAL OPERATION, STEP-BY-STEP ..................... 15

A. Main Screen ............................................................. 15

A. Daily Startup Procedure ......................................... 16

B. Daily Shutdown Procedure ..................................... 16

III. QUICK REFERENCE: TROUBLESHOOTING ......... 17

IV. SCREEN ALERTS ................................................... 17

SECTION 4

MAINTENANCE .................................................................. 18

I. MAINTENANCE - DAILY .............................................. 1 8

II. MAINTENANCE - MONTHLY ....................................... 19

III. MAINTENANCE - EVERY 3 MONTHS ........................ 20

IV. MAINTENANCE - EVERY 6 MONTHS ....................... 21

V. KEY SPARE PARTS KIT ............................................. 22

SECTION 5

ELECTRICAL WIRING DIAGRAM ...................................... 23

I. WIRING DIAGRAM, 870 GAS OVEN, 208/240V,

50/60 Hz, 1 Ph ............................................................... 23

4

567

ITEM QTY P/N DESCRIPTION

1 1 55028 STOP,BACK SIDE CONV EXT

2 1 55027 STOP,SIDE END CONV EXT

3 1 59026

4 1 42612 KIT,SUPPLEMENT SVC AGENCY LIST

5 1 33120-0056 PIPE,BLK 1-1/4" X 54"

6 1 22450-0130 BAG,POLY4MIL 9" X 12"W/MINI-GRIP

7 1 59155 BUSHING,HEYCO SB 1500-18

8 1 59099 Reflector

9 1 59098 Bracket, Reflector

10 1 59226 WLDMT, Bracket Reflector

11 2 48522 Spacer, 1.5" Dia X 1.125" H

12 2 19A15144 SCR, MS HH 10-32 X 1-1/4 18-8

OWNER'S OPERATING &
INSTALLATION MANUAL

8

9

D. STANDOFF INSTALLATION

1 Place screw, P/N 19A15144, through counter-bored hole in

standoff, P/N 48522, and screw into weld nut on rear shroud.

2. Repeat procedure for both sides.

10

CONVEYOR BELT REVERSAL

Conveyor belt reversal consists of four steps:

1. Physically reversing the conveyor belt.

2. Moving the lower thermocouple.

3. Resetting direction jumper on the conveyor control board.

4. Switching the photo detector.

Mount the new reflector bracket to the provided holes on the
front right-hand side of the oven. The reflector should be
positioned just above the conveyor belt.

Using an assistant, hold both back cover switches in the
closed position. This will allow power to the photo-eye, and it
will provide a red beam for aiming. Loosen one of the screws
holding the photo detector gimbal tight, allowing it to be
reaimed at the reflector. The beam should hit exactly in the
center of the reflector, then tighten the screw back down.

Note: This is MUCH easier in reduced light.

Replace all covers.

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.

MOVING THE LOWER THERMOCOUPLE

The lower thermocouple needs to be moved from the lower
outer most hole to the opposite side lower outer most hole.
The thermocouple electrical connection needs to be moved
as well. Insert the thermocouple (TC2) into the thermocouple
hole left open by the removal of the coverplate. Secure the
thermocouple (TC2 and rename TC3) with the two (2) 6-32
screws that were removed previously. Secure the coverplate
with the two (2) 6-32 screws over the hole where the thermo­couple (TC2) was removed.

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.

SWITCHING PHOTO DETECTOR

Remove both rear fan belt covers, then remove the motor cover
assembly from both sides of the oven. The photo eye is located
on the front side of the left motor bracket. Disconnect the three
connecting wires, noting which color wires assemble to the
associated wires on the photo-detector. Remove the entire
photo detector bracket. Replace the assembly to the right­hand side of the unit, mirroring the way it was assembled on
the left. Reconnect the detector wiring in the same order it was
on the left.

Incoming electrical power lines are fed through the strain­relief fitting, shown in Figure 2-12. 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 either of the blower
or rear shrouds is removed.

11

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.

12

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 a 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.).

D. PS870 Propane conversion

Four items have to be changed, to change the oven to LP:

1. Adjust internal burner air shutters.

2. Replace main Orifices

3. Replace (and adjust) the spring in the main valve (see LP kit)

4. Adjust modulating valve bypass settings.

Disconnect the manifold unions closest to the main burner,
and remove the manifold assemblies (four screws each).
Remove the addition four screws holding the burner cores and
slide out each burner core (leaving the ignition and sense
wires connected). Adjust the internal air shutters fully open,
and replace the cores.

Replace the main orifices on the manifold assemblies with the
LP units, and replace the manifold assemblies. Reconnect the
unions. Replace the valve spring with the LP spring, and adjust
the downstream pressure to get 7″ WC.

Adjust the bypass screws in the side of each modulating valve
to approximately 1/6 turn from fully closed. If this setting is too low,
the burners will shut off when trying to modulate. If it is too open,
the unit will tend to gradually raise up in temperature at standby.

Figure 2-14 - Gas Burner/Blower Motor and Piping Assembly

Gas Burner

13

Burner/Blower Motor

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 both right and left sides 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.

14

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.

Figure 3-1 Screen Saver

2. Push the “ON/OFF” button to start the oven. The
controller will display the screen, as shown in
Figure 3-3.

ON/OFF button

Figure 3-3 Main Screen ON

3. To change the temperature, push the “TEMP” button.
The controller will display the screen, shown in
Figure 3-4. To change the left temperature, push the

←←

“

←” arrow button. Then push either the “↑” arrow or “↓”

←←

arrow buttons to increase or decrease temperatures
respectively. To change the right temperature, push
the “→” arrow button. Then push either the “↑” arrow or
“↓” arrow buttons to increase or decrease tempera­tures accordingly. When the proper temperatures are
entered, push the “Enter/Reset” button. The controller
will now show the display shown in Figure 3-3.

Figure 3-2 Main Screen OFF

TEMP Set button

Figure 3-4 Temperature Screen

15

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.

Message Bar

ON/OFF button

Energy Level Indicators

TEMP button

TIME button

Figure 3-5 Belt Speed Screen

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 right and left
hand oven settings. Set temperatures 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.

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. Right actual temperature - Indicates current average
temperature of the right side of the oven.

2. Left actual temperature - Indicates current average
temperature of the left side of the oven.

3. Set point temperature - Pressing on this value allows
the user to adjust the set point of the oven.

4. 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
1500 RPM, while the oven maintains temperature and belt
speed.

16

III. QUICK REFERENCE: TROUBLESHOOTING

SYMPTOM PROBLEM SOLUTION

Oven will not

turn On.

Oven will not

heat.

Oven is operating, but

little or no air is coming

from the fingers.

Conveyor will not move.

No electrical power • Check that the circuit breaker/fused disconnect is on. Make

sure the emergenct stop button is on.

No gas pressure

Burner did not light

Air fingers may be as­sembled incorrectly after
cleaning.

Oven is not up to operating
temperature.

Conveyor may be jammed.

• Make sure main gas is on.

• 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.

IV. SCREEN ALERTS

SYMPTOM PROBLEM SOLUTION

Battery Symbol in the

lower right hand corner

The internal battery needs
to be replaced to retain
energy mode timings.

• A qualified service technician should accomplish this.

High Control Compart-

ment Temperature

Main Blower problem or

Combustion Blower

problem.

Control Over Temp Front filters are clogged • Clean or replace filters.

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

Energy saving mode 2 Normal Operation

Clean and replace the
front fan filters.

The computer has
detected a problem with
either the main, or burner
blowers.

PLC malfunction

temperature

• Failure to do this will eventually shut down the oven due to
excessive temperature.

• This should be corrected by a qualified service technician.

• If no obstruction, call service.

• If no obstruction, call service.

Energy saving Mode 3 Normal operation

17

181920

E. Blower Belts

1. To gain access to each blower belt compartment remove
the four screws shown in Figure 4-8. Then, lift the rear
shroud off its hangers.

If access to the blower motors is required, remove the
three mounting screws (two on the front of each shroud
and one on the rear). Then, lift the end shroud straight up
and off its hangers.

2. Check each blower belt for cracking or excessive wear.

3. Check for amount of belt deflection in the center of the belt,
1/2″ deflection is acceptable, see Figure 4-9.

4. If necessary, replace belt.

IV. MAINTENANCE - EVERY 6 MONTHS

A. Check that the oven is cool and the power is disconnected

as described in the warning at the beginning of this Section.

B. For gas ovens, clean and inspect the burner nozzel and

electrode assembly.

C. Check (and clean, if necessary) the oven venting system.

D. Check the conveyor drive shaft bushings and spacers.

Replace the components if they are worn.

Figure 4-9 - Belt Deflection

21

ITEM QTY. P/N DESCRIPTION

1 1 59081 DIGITAL DISPLAY, PROGRAMMED

2 1 58678 MOTOR, CONVEYOR DRIVE

3 1 58679 CONVEYOR CONTROL BOARD

4 2 59168 INVERTER, PROGRAMMED

5 1 M9608 POWER SUPPLY

6 1 59337 KIT, THERMOCOUPLE (6 THERMOCOUPLES)

7 2 M9616 FAN, COOLING

8 2 57288 MOTOR, BLOWER

9A 1 57141 AIR SWITCH BURNER/BLOWER MOTOR

9B 2 50610 AIR SWITCH MAIN BLOWER

10 1 54727 IGNITION MODULE

11 1 M9887 ASSEMBLY, BURNER BLOWER/MOTOR

12 2 41647 VALVE, MODULATING GAS, 1/2"

13 2 31651 AMPLIFIER, MODULATING VALVE

14 1 33983 HIGH LIMIT CONTROL MODULE, 240V

15 2 32108 TRANSFORMER, 240Vp:24Vs

16 1 59109 PLC MODULE, PROGRAMMED

17 1 58668 THERMOCOUPLE MODULE

18 1 58669 CURRENT MODULE

19 1 59112 PHOTOCELL

12 345

10

15

16, 17, 18

19

Wiring Diagrams (electrical schematics)

54745 Rev. I

Middleby-Marshall Model Number G208-240 volt 50/60 Hz, 1 Phase

24