Middleby Marshall PS520G User Manual

MiddlebyMiddleby

Middleby

MiddlebyMiddleby
MarshallMarshall

Marshall

MarshallMarshall

A MIDDLEBY COMPANY

owner's
operating

& installation

manual

PS520-Series Gas Ovens: English

October 17, 2006

®

PS520-Series

Model

PS520G

OVENS

PS520 (Single)

PS520 (Double)

©2006 Middleby Marshall Inc.

PS520 (Triple)

Part No. 59223

Price $30.00

P: 10/06

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
instructions are 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,

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
instructions thoroughly before installing or servicing this
equipment.

NOTICE

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

Contact your authorized Service Agency to perform maintenance and

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

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

Middleby Marshall (Manufacturer) reserves the right to

NOT VALID

unless the oven is installed, started, and

NOTICE

NOTICE

NOTICE

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

O QUIBBLE LIMITED WARRANTY

N

(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 PS520 GAS SPECIFICATIONS ............................ 2

II. COMPONENT FUNCTION ............................................. 4

A. Conveyor Motor and Conveyor Belt ........................ 4

B. Blower Fan ................................................................. 4

C. Gas Burner ................................................................ 4

D. Cooling Fan ................................................................ 4

E. Air Fingers and Blank Plates - See Figure 1-9 ........ 4

SECTION 2

I. UNLOADING ................................................................... 8

PARTS LIST FOR SERIES PS520 GAS OVEN

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

UTILITY ROUGH-IN DIMENSIONS AND POSITIONING

FOR PS520-SERIES OVENS .................................... 13

CIRCUIT BREAKER ..................................................... 13

ELECTRICAL SPECIFICATIONS ................................. 13

ELECTRICAL RATING ................................................. 13

SUPPLY WIRE .............................................................. 13

SUGGESTED ................................................................ 13

II. VENTILATION GUIDELINES ........................................ 1 3

III. ELECTRICAL CONNECTION INFORMATION FOR

PS520-SERIES OVENS. ........................................... 14

IV. ELECTRIC SUPPLY FOR GAS HEATED OVENS ..... 14

V. GAS SUPPLY .............................................................. 15

SECTION 3 INSTALLATION

I. CONTROL FUNCTIONS ................................................ 1 7

II. COMPONENT INFORMATION AND LOCATION ......... 18

A. Door Safety Switch .................................................. 18

B. Blower Switch .......................................................... 18

C. Heat Switch .............................................................. 18

D. Temperature Controller .......................................... 18

E. Conveyor ................................................................. 19

MEASURING CONVEYOR SPEED. ............................. 19

Page

TABLE OF CONTENTS

(Continued)

Page

III. STEP-BY-STEP OPERATION ....................................... 20

A. Startup Procedures ................................................. 20

Daily Startup ................................................................. 20

Power Failure ............................................................... 2 0

B. Shutdown Procedure ............................................... 20

IV. NORMAL OPERATION - STEP-BY-STEP ................... 22

A.Daily Startup Procedure ........................................... 22

B. Daily Shutdown Procedure ...................................... 22

V. QUICK REFERENCE: TROUBLESHOOTING ............ 24

SECTION 4 MAINTENANCE

I. MAINTENANCE - DAILY ............................................ 26

A. Exterior ..................................................................... 2 6

B. Cooling Fan ............................................................... 26

C. Conveyor Belt .......................................................... 26

D. Crumb Pans ............................................................. 26

II. MAINTENANCE - MONTHLY ....................................... 27

A. Removing Conveyor From Oven For Cleaning ..... 27

B. Air Fingers Disassembly For Cleaning .................. 29

C. Reassembly of Air Fingers ..................................... 30

D. Reinstall End Plugs ................................................. 33

E. Conveyor Reassembly Into Oven .......................... 34

F. Checking Conveyor Belt Tension ........................... 34

G. Conveyor Belt Link Removal ................................. 35

H. Attaching Drive Chain ............................................. 36

III. MAINTENANCE - EVERY 3 MONTHS ......................... 37

A. Electrical Terminals ................................................ 37

B. Ventilation ................................................................ 37

IV. MAINTENANCE - EVERY 6 MONTHS ........................ 37

PS520-SERIES GAS OVEN KEY SPARE

PARTS ....................................................................... 38

KEY SPARE PARTS KIT ............................................... 38

SECTION 5 TROUBLESHOOTING

Troubleshooting Charts ...................................................... 3 9

SECTION 6 ELECTRICAL SCHEMATICS

Wiring Diagram, G208-240V 50/60 GO, PS520 ............... 41

iv

NOTE

Wiring Diagrams are in Section 6 of this Manual.

The diagram for each oven is also on the lower

inner surface of its Control Console.

SECTION 1

DESCRIPTION

I. MODEL IDENTIFICATION

The Middleby Marshall PS520-Series may be used either
as a single oven or stacked for use as 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,

consists of three stacked single ovens. The lower oven is
mounted on a base pad with stacking pins.

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.

single ovens. A triple oven (Figure 1-3)

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. (0.23 sq. m.)

Overall Dimension – Standard Single Oven w/Legs 42.00″ (1067mm) L ×

Overall Dimension – Double Oven 42.00″ (1067mm) L ×

Overall Dimension – Triple Oven 42.00″ (1067mm) L x

Weight of Single Oven 250 lb (93.3kg)

Shipping Weight 325 lb (121.3kg)

Shipping Cube 22.1 ft3 (0.62 m3)

Operating Range 8.3 kW/hr

BTU's – Natural or Propane Gas 40,000 BTU/HR

Gas Input – Natural or Propane Gas 1/2″ NPT

Maximum Operating Temperature 600°F (316°C)

Warm-up Time 20 min.

Belt Speed Limits 1-10 minutes

35.21″ (894mm) W ×

21.10″ (536mm) H ×

35.21″ (894mm) W ×

36.64″ (931mm) H x

35.21″ (894mm) W ×

48.19″ (1224mm) H ×

SERIES PS520 ELECTRICAL SPECIFICATIONS

Main Blower & Control Circuit Phase Frequency Amperage Poles Wires

Elements Voltage Voltage Draw

208-240V 208-240V 1 Ph 50/60 Hz 1.5 Amp 2 Pole 3 Wire

GAS ORIFICE AND PRESSURE SPECIFICATIONS (PER OVEN CAVITY) - DOMESTIC AND STANDARD EXPORT OVENS

Gas Type Main Orifice I.D. Bypass Orifice I.D. Supply (Inlet) Pressure Pressure

Natural 0.082” (2.08mm, #45 drill) 0.073” (2.0574mm, #49 drill) 6-12” W.C. (14.9-29.9mbar) * 3.5” W.C. (8.72mbar)

Propane 0.057” (1.45mm, #46 drill) 0.052” (1.85mm, #55 drill) 11-14” W.C. (27.4-34.9mbar) * 7” W.C. (17.44mbar)

*

The gas supply pressures and orifice sizes shown are for ovens installed in North America. The required gas supply pressures and orifice
sizes of ovens installed in other locations are dependent on the local gas type and on all applicable local codes.

GAS ORIFICE AND PRESSURE SPECIFICATIONS (PER OVEN CAVITY) - CE OVENS

Supply (Inlet) Pressure

Gas Orifice DK,FI 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 2.3749 20 20 20 -- -- 11.21 22.36

mm mbar mbar mbar mbar kW-hr.

G25 2.3749 -- -- -- -- -- 16.19 22.36

mm mbar kW-hr.

G30 1.3970 -- -- -- 29 or 50 28-30, 37 26.2 22.59

mm mbar or 50 mbar mbar kW-hr.

IT,PT,ES,SE,

I

2H

I

2E

I

2E+

I

3B/P

I

3+

Pressure Input

(2 hot, 1 grd)

Orifice (Manifold)

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.

Additional electrical information is provided on the oven's serial plate.

This Manual Must Be Kept For Future Reference.

2

II. COMPONENT FUNCTION (Figure 1-4)

SECTION 1

DESCRIPTION

Figure 1-4. PS520-Series Oven Components Locations

3

SECTION 1
DESCRIPTION

II. COMPONENT FUNCTION

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 3 minutes to 30 minutes; this is the time
that a product can take to pass through 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. Gas Burner

The gas burner is located inside the rear panel and is
controlled by the temperature controller.

D. Cooling Fan — See Figure 1-5 and Figure 1-6

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 1-7

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 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.

Blower Assembly

Right Control Box

Figure 1-5. Machinery Compartment

Components

4

SECTION 1

DESCRIPTION

Figure 1-6. Cooling Fan

5

SECTION 1
DESCRIPTION

Half Blank Plate

F2. Blank Plates

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

Outer Plate

Blank Plate

Inner Plate

Finger
Manifold
Assembly

Baffle

Figure 1-7. Blank Plates (two sizes) and an Air Finger.

6

SECTION 2

SECTION 2

INSTALLATION

INSTALLATION

WARNING - For gas ovens, after any conversions, readjustments, or service work on the oven:

• Perform a gas leak test.

• Test for correct air supply.

• Test for proper combustion and gas supply.

• Check that the ventilation system is in operation.

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

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.

Description

section of

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 with local codes. In the absence of local codes, gas oven

installations must conform with the National Fuel Gas Code, ANSI Z223.1. Installed ovens 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. Installed ovens must be electrically grounded in

accordance with local codes, or in the absence of local codes, with the Canadian Electrical Code CSA C22.2.

NOTE

In Australia, the oven installation must conform with any requirements of the appropriate statutory authority.

Gas oven installtions must conform with AGA Codes AG311 and AG601.

NOTE

In CE countries, all aspects of the gas supply connection must comply with current IEC/CEE requirements and

with all applicable local, national, and international codes. In addition, four casters are provided to allow the oven

to be more easily moved to the installation location. These casters are intended to simplify pre-installation

movement only, and are NOT suitable for use as part of a CE oven installation. During the installation procedure,

the casters MUST be removed, so that the oven can be supported by the supplied 152mm adjustable legs.

7

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 be provided
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″ (1124mm) Long ×

37-1/2″ (953mm) Wide ×

23″ (584mm) 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.

PARTS LIST FOR SERIES PS520 GAS OVEN

INSTALLATION KIT

Single Stack Oven

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 × 1/2, 18-8
6 1 59223 OWNER'S OPERATING & INSTALLATION MANUAL
7 1 22450-0228 GAS HOSE RESTRAINT CABLE
8 1 22361-0001 GAS HOSE

P/N 59182

7

8

Figure 2-1. PS520-Series Gas Oven Installation Parts

8

INSTALLATION

PARTS LIST FOR SERIES PS520 Gas OVEN

INSTALLATION KIT

Double Stack Oven

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 × 1/2, 18-8
5 4 3101908 LEG 4″ AD FT
6 1 59223 OWNER'S OPERATING & INSTALLATION MANUAL
7 1 22450-0228 GAS HOSE RESTRAINT CABLE
8 2 22361-0001 GAS HOSE

P/N 59183

SECTION 2

7

8

PARTS LIST FOR SERIES PS520 Gas OVEN

INSTALLATION KIT

Triple Stack Oven

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 × 1/2, 18-8
5 4 M3828 PIN, ALIGNMENT
6 1 59223 OWNER'S OPERATING & INSTALLATION MANUAL
7 1 22450-0228 GAS HOSE RESTRAINT CABLE
8 3 22361-0001 GAS HOSE

P/N 59184

7

8

Figure 2-1 (continued). PS520-Series Gas Oven Installation Parts

9

SECTION 2
INSTALLATION

1

Figure 2-5. MODEL PS520 SINGLE OVEN DIMENSIONS

4.00

101.6mm

The Opening Height is Adjustable from 2-1/4 inch minimum

1

to 3-3/4 inch maximum in 1/2 inch increments.

10

SECTION 2

INSTALLATION

Figure 2-6. MODEL PS520 DOUBLE OVEN DIMENSIONS

1

4.00

101.6mm

The Opening Height is Adjustable from 2-1/4 inch minimum

1

to 3-3/4 inch maximum in 1/2 inch increments.

2

P/N 59927 is shown in its correct installed position.

11