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.
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 Width32″ (813mm)
Heating Zone Length40-1/2″ (1028mm)
Baking Area Square Feet9 sq. ft. (0.84 sq. m.)
Overall Dimension
Standard Single Oven w/Legs80″ (2032mm) L ×
Overall Dimension
Double Oven80″ (2032mm) L ×
Overall Dimension
Triple Oven80″ (2032mm) L x
Weight of Single Oven925 lb (419kg)
Shipping Weight1,100 lb (498.3kg)
Shipping CubeApprox. 132 ft3 (3.74 m3)
Operating Range110,000 BTU/hr
Maximum Operating Temperature550°F (287°C)
Warm-up Time10 min.
Gas Oven Inlet Line Size3/4″ (19mm) ID for each oven
Minimum Gas Meter Rating450 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
Natural6″ to 12″ Water Column (13.8 to 29.9 mbar)
Propane11.5″ to 12″ Water Column (28.7 to 29.9 mbar)
Gas Valve0.75″ (19mm) ID full-flow, gas, shutoff valve installed in oven inlet gas line.
Recirculating Air FanOne fan at 2300 RPM
Air Velocity3000 fpm (1524 cm/sec) (Average)
Bake Time3 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 CircuitPhaseFrequencyAmperagePolesWires
Elements VoltageVoltageDraw
208-240V208-240V1 Ph50/60 Hz4.1 Amp3 Pole3 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.
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.
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
23/4″ (19mm) × 3″ (76mm) NIPPLE
33/4″ (19mm) FULL FLOW GAS SHUTOFF VALVE
42″ (51mm) × 3/4″ (19mm) 90° REDUCER ELBOW
52″ (51mm) ID GAS SUPPLY PIPE LINE - NATURAL GAS
615 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
SECTION 2
INSTALLATION
Electrical Junction
Cover Plate
Figure 2-12. Junction Connection Box
V. GAS SUPPLY FOR GAS HEATED
OVENS
WARNING
During gas line pressure testing, observe the
following precautions:
1. The oven
MUST be disconnected from the gas supply
piping system during any pressure testing of
that system at test pressures in excess of
1/2 psig (3.45kPa).
2. The oven MUST be isolated from the gas
supply piping system, by closing its individual
shutoff valve, during any pressure testing of that
system at test pressures equal to, or less than,
1/2 psig (3.45kPa).
3. If incoming gas line pressure exceeds
14″w.c. (35mbar), a separate regulator MUST be
installed in the line on the inlet side of the safety
valve for the oven.
and its individual shutoff valve
CAUTION
To prevent damaging the control valve regulator
of the oven during initial turn-on of gas, the
individual shutoff valve MUST be opened
slowly.
shutoff valve should remain open except during
gas line pressure testing (refer to the preceding
WARNING) and during necessary servicing and
maintenance procedures.
After initial turn-on of gas, the individual
very
Check the oven data plate (Figure 2-11) before making any
gas supply line connections. The type of gas (natural or
propane) being supplied to the oven must agree with data
on the oven data plate.
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
PS540-Series oven is equipped with casters for accessibility during servicing, 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.), or, if applicable, Connectors for Movable Gas
Appliances, CAN/CGA-6.16 (in Canada), 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.), or, if applicable, Quick-Disconnect Devices for Use With Gas Fuel, CAN6.9 (in Canada).
One gas line connection method is shown in Figure 2-13;
however, the preceding requirements must be satisfied.
The 90-degree elbow and the union shown in Figure 2-13
are not furnished; however, the flexible gas line is part of
the installation kit.
On an oven equipped with casters, a cable restraint
assembly must be installed to limit the movement of the
appliance, without depending on the connector and quickdisconnect device or its associated gas line installation.
The location where the Cable Restraint Assembly is to be
attached to the oven is illustrated in Figure 2-8.
20
A. Connection
Check the oven’s gas supply requirements before making the
gas utility connection. Gas supply requirement are listed on
the oven’s serial plate and in Table 1-4. Gas Orifice and
Pressure Specifications (in Section 1, Description).
Check the serial plate to determine the type of gas (Propane
or Natural) to be used with the oven.
Refer to the instructions in the gas hose package (included
in the Installation Kit) before connecting the gas line. One
gas line connection method is shown in Figure 2-18;
however, compliance with the applicable standards and
regulations is mandatory.
Inlet, regulated, and pilot gas pressure readings can be
taken using a digital tube manometer at the tap location shown
in Figure 2-19. Figure 2-19 shows the burner assembly and
Figure 2-21 shows the gas valve.
NOTE:
The installation must conform with local codes or in
the absence of local codes, with the National Fuel
Gas Code, ANSI Z223.1-latest edition.
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 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.).
SECTION 2
INSTALLATION
1/2″ gas
pipe nipple
1/2″ gas line
tee with
pressure tap
Quick-
disconnect
device
Figure 2-13. Flexible Gas Hose Installation
3/4″-1/2″
gas pipe
reducer
3/4″ gas
pipe nipple
90°
Elbow
Flexible
Gas Hose
To Gas
Supply
Pipe
Individual gas
connection for
each oven
Full-Flow
Gas
Shutoff
Valve
cavity
B. Gas Conversion
Where permitted by local and national codes, it is possible
to convert ovens from natural to propane gas, or from
propane to natural gas. Use the appropriate Middleby Gas
Conversion Kit for the specific oven model.
CAUTION: The terms of the oven’s warranty require all start-
ups, conversions and service work to be performed
by a Middleby Authorized Service Agent.
C. PS540 Propane Conversion
Two items have to be changed, to change the oven to LP:
1.Replace main orifice.
2.Adjust main gas regulator per instructions below.
Disconnect the manifold union closest to the main
burner, and remove the manifold assembly. Replace
the main orifice.
Replace the main orifice on the manifold assemblies with the
LP units, and replace the manifold assembly.
2.Connect a suitable pressure gauge to pipe line or to outlet pressure
tap of gas control concerned, to measure burner pressure (measuring point must be as near to burner as possible).
Figure 2-14. Gas Burner Assembly
3.Make sure that the appliance is in operation and the
Moduplus® coil is energized with maximum current.
4.If maximum rate pressure needs adjustment, use an 8 mm
wrench to turn adjustment screw for maximum pressure
setting (clockwise to increase or counter-clockwise to
decrease pressure), until the desired maximum outlet
pressure is obtained.
5.Disconnect electrical connection of the Moduplus®.
6.Check minimum pressure setting and readjust if necessary. (See Adjusting Minimum Pressure Setting for
proper adjusting procedure.)
2.Connect a suitable pressure gauge to pipe line or to outlet
pressure tap of gas control concerned, to measure burner
pressure (measuring point must be as near to burner as
possible).
®
3.Disconnect electrical connection of the Moduplus
.
4.Energize operator, set control in operation and wait until
an outlet pressure is recorded on pressure gauge.
5.If minimum rate pressure needs adjustment, use an 8 mm
wrench to turn adjustment screw for minimum pressure
setting (clockwise to increase or counter-clockwise to
decrease pressure), until the desired minimum outlet
pressure is obtained.
6.Check if main burner lights easily and reliable at minimum pressure.
After any adjustment, set appliance in operation and
observe through a component cycle to ensure that burner
system components function correctly.
Gs. Maintenance
It is recommended to check yearly the minimum and the
maximum setting and readjust them if necessary.
VI. CONVEYOR REAR STOP AND END
STOP INSTALLATION
Locate the conveyor rear stop and end stop in the
installation kit. Install the rear stop and end stop at the exit
end of the oven. See Figure 2-17.
Conveyor Rear Stop
id
M
a
Conveyor End Stop
M
l
d
s
r
Figure 2-16. Gas Valve
Figure 2-17. Installing Rear and End Stops
22
I. CONTROL FUNCTIONS
SECTION 3
OPERATION
SECTION 3
OPERATION
Figure 3-1. PS540-Series Oven Control Functions
WARNING
The burner cannot operate and gas cannot flow
through the burner without electric power. Do
NOT attempt to operate the oven during a power
outage.
WARNING
A possibility of injury from rotating parts and
electric shock exists in this oven.
Never disassemble or clean the oven with the
BLOWER switch or any other oven control turned
“ON” or “I”. Turn “OFF” or “O” and lockout or
tagout all electric power to the oven before
attempting to clean or service this oven.
23
SECTION 3
OPERATION
II. COMPONENT INFORMATION AND
LOCATION (Figures 3-1 and 3-2)
A. Door Safety Switch
The Door Safety Switch is located at the lower left side of
control panel opening. Opening the control panel door
permits this switch to open, disconnecting power to all
electrical controls.
CAUTION
Do NOT touch the wires going to this safety switch.
Current is always present.
B. Blower Switch
The blower switch has two positions. The switch must be
“ON” or “I” for the burner to come on and permit the oven
to warm up. The fan circulates the air throughout the oven
and must stay on during baking and during the cool down
cycle above 200°F (93°C) to prevent blower bearing
damage. To protect the blower motor and bearings a
thermostatic override is built into the oven. If the temperature inside the oven is over 180°F (82°C) the main blower
will continue to run after the blower switch is turned to the
“OFF” or “O” position.
An air pressure switch monitors the air flow from the
blower, acting as a safety interlock for the burner. The
burner cannot light, if the air switch does not sense air flow
off the main blower fan.
C. Heat Switch
Turning the HEAT switch to “ON” or“I” will initially set up
the oven purge circuit. After approximately 30 seconds,
the burner lights. After the burner is lit, a flame sensor
sends a signal to the ignition module to stop the spark.
The burner will run unless the flame sensor does not
detect a flame or the heat switch is turned to the “OFF”
or “O” position.
The HEAT switch is in series with the burner blower motor
centrifugal switch, the high-temperature safety switch,
and the blower fan air pressure switch. All three safety
switches must be closed for gas to flow and the burner to
light.
D. Temperature Controller
The temperature controller is a solid-state, on/off type to
maintain the operator-set temperature. The temperature
controller continuously monitors the oven temperature and
turns on the modulating solenoid valve in a gas-heated
oven. The heat is on for the time required to maintain a
constant oven temperature.
The temperature controller contains a low-limit switch
which allows the oven to cool down to 200°F (93°C) before
shutting off the blower. A high-limit indication (ALM 1) will
appear on the display if the oven reaches 650°F (343°C).
Figure 3-2. Interior View of Machinery Compartment and Control Console
24
E. Conveyor
The on-off switch for the conveyor motor is on the control
panel. Also on the control panel is the digital conveyor
speed control. The digital control can be adjusted from 3
min. to 30 min. bake time (conveyor speed). Refer to
Figure 3-3.
Conveyor speed is measured by the amount of time it
takes for an item to go through the bake chamber of the
oven.
MEASURING CONVEYOR SPEED.
SECTION 3
OPERATION
See Figures 3-4 and 3-5.
To check conveyor speed, place a product item at the
entrance end of baking chamber as shown. Time how long
it takes for the leading edge of the item to go from the
entrance end of the baking chamber to the exit end. This
should be the conveyor speed shown on the conveyor
speed digital control.
NOTE: In Figures 3-4 and 3-5, the oven shown is with the
conveyor running right to left.
WARNING
The burner will not operate and gas will not flow
through the burner without electric power. No
attempt should be made to operate the oven
during power failure.
WARNING
Possibility of injury from rotating parts and
electrical shock exist in this oven.
Never disassemble or clean the oven with the
blower switch or any other part of the oven
turned “ON” or “I”. Turn “OFF” or “O” and
lockout or tagout all electrical power to the
oven before attempting to clean or service
this oven.
Figure 3-3. Conveyor Speed Digital Control
Figure 3-4. Product at entrance end of baking
chamber – BEGINNING OF TIMING
25
Figure 3-5. Product at exit end of baking
chamber – END OF TIMING
SECTION 3
OPERATION
WARNING
OVEN MUST BE KEPT CLEAR OF
COMBUSTIBLES AT ALL TIMES.
III. STEP-BY-STEP OPERATION
Control Panel (On split belt ovens, two conveyor speed
controls are mounted on the control panel.)
A. Startup Procedures
Initial Startup
Check that the full-flow gas shutoff valve is “on”.
This valve is located outside the rear of the oven. See
Figures 2-3, 2-4, and 2-5.
Daily Startup
1. Turn the BLOWER switch (Figure 3-6) to the “ON” or “I”
position. This starts the main blower fan and the cooling
fan. The blower circulates air through the air fingers and
must stay on during the cooking or baking process.
2. Check to see if the cooling fan (see Figure 1-8) is
operating when the blower switch (see Figure 3-6) is turned
“ON” or “I”. The cooling fans cool the control components
and burner blower motor. The cooling fan, located at the
rear of the electrical control cabinet blows air into and
through the cabinet. Air is exhausted through the front of
the cabinet and also out the front of the oven. Refer to Daily
Maintenance Section for fan intake checking procedure.
IMPORTANT NOTE
The cooling fan operates when the BLOWER
switch is turned “ON” or “I”. It must operate to keep
the control console below 140°F (60°C).
5. Turn the HEAT switch (Figure 3-6) to the “ON” or “I”
position. This completes a circuit to supply electric power
to the burner. When an oven that has not been in operation
for approximately 1/2 hour is turned on, it goes through a
30-second purge cycle. The burner blower motor will not
operate during the time the blower fan is purging the oven.
After 30 seconds, the burner blower motor starts, which
can be detected by feeling a slight vibration when touched.
This permits the burner to light.
When in operation, the burner is either on low or high flame.
Its flame-sensing electrode must be satisfied to keep the
bypass and gas valves open. If for some reason the
bypass flame is extinguished, the burner tries to relight for
90 seconds. If the burner flame does not relight in 90
seconds, the oven goes into automatic safety lockout.
To relight the oven, turn the HEAT switch to “OFF” or “O”
for 5 minutes. Then, repeat the Oven Startup procedure.
6. Close front window.
7. Oven will reach a baking temperature of 600°F (315°C)
in approximately 10 minutes. Allow the oven to cycle for
30 minutes after it has reached desired bake temperatue.
The oven is now ready for baking.
Power Failure
In case of power failure, turn off all switches; open oven
window and remove product. After power has been
reestablished follow normal startup procedure.
CAUTION
The burner will not operate and gas will not flow
through the burner without electric power. No
attempt should be made to operate the oven
during power failure.
3. Turn the CONVEYOR switch (Figure 3-6) to the “ON” or
“I” position. This starts the conveyor belt moving through
the oven. Set the conveyor speed for the desired baking
time. Refer to the following Procedures E, F and G.
4. Set the temperature controller to the desired baking
temperature. See section on bake times to determine
desired temperature.
NOTE: For complete temperature controller operation
instructions refer to Step C.
B. Shutdown Procedure
1. Turn the BLOWER and HEAT switches to “OFF” or “O”.
NOTE: The blowers will remain on until the oven temperature cools down to 200°F (93°C) at which time they will stop
automatically.
2. Make certain that there are no products left on the
conveyor inside the oven. Turn the CONVEYOR switch
to “OFF” or “O”.
3. Turn off the main gas supply valve.
4. Open the oven window.
26
SECTION 3
OPERATION
Figure 3-6. Control Panel
27
SECTION 3
OPERATION
II. NORMAL OPERATION - STEP-BY-STEP
A.Daily Startup Procedure
1.Check that the circuit breaker/fused disconnect is in the
on position. Check that the window is closed.
2. Turn the "BLOWER"
() switch to the “ON”
("I") position.
3.Turn the "CONVEYOR"
() switch to the
“ON” ("I") position.
4.If necessary, adjust the
conveyor speed setting
by pressing the
pushbuttons on the conveyor speed controller to
change the displayed
bake time.
5. Adjust the temperature
controller to a desired set
temperature, if necessary.
•Press the Set Point
and Unlock keys at
the same time. Wait
for the "SET PT" light
to turn on.
or
+
or
wait
for
7.Wait for the oven to heat to the setpoint temperature.
Higher setpoint temperatures will require a longer wait.
The oven can reach a temperature of 500°F (232°C) in
approximately 5 minutes.
8.(Optional) Press the Temperature (
the Actual Temperature
in the display, and wait
for the "ACTUAL TEMP"
light to turn on. This allows you to monitor the
oven temperature as it
rises to the setpoint.
9.Allow the oven to preheat for 10 minutes after it has
reached the set point temperature.
B. DAILY SHUTDOWN PROCEDURE
1.Turn the "HEAT" (
"BLOWER" (
ches to the "OFF" ("O")
position. Note that the
blowers will remain in operation until the oven has
cooled to below 200°F
(93°C).
2.Make certain that there
are no products left on
the conveyor inside the
oven. Turn the "CONVEYOR" (
the "OFF" ("O") position.
) key to show
) and
) swit-
) switch to
wait
for
+
•Press the Up Arrow
and Down Arrow
Keys as necessary
to adjust the setpoint.
6. Turn the "HEAT" ()
switch to the "ON" ("I")
position, and wait for the
"HEAT ON" light to turn
on.
or
wait
for
3.Open the window to allow the oven to cool faster.
4.After the oven has cooled and the blowers have turned
to the “OFF” or “O” position, switch the circuit breaker/fuse
disconnect to the “OFF” or “O” position.
CAUTION
In case of power failure, turn all switches to the “OFF”
("O") position, open the oven window, and remove
the product. After the power has been restored,
perform the normal startup procedure. IF THE OVEN
WAS SWITCHED OFF FOR LESS THAN 5 MINUTES,
WAIT FOR AT LEAST FIVE MINUTES BEFORE RESTARTING THE OVEN.
The burner will not operate and gas will not flow
through the burner without electric power. No
attempt should be made to operate the oven during
a power failure.
28
SECTION 3
OPERATION
"SP LOCK"
Light
Lights when the
set point is locked
out from changes.
This setting can
only be changed by
service personnel.
OVERTEMP
Light
Lights when the oven
temperature is
greater than 650°F
(343°C). Refer to
Quick Reference:
Troubleshooting in
this section.
Display
Shows the Set Point
or the Actual Tem-
perature in degrees
Fahrenheit (F) or
Celsius (C).
"HEAT ON"
Light
Lights when the
burner is in
operation.
"SET PT"
(setpoint)
Light
Lights when the
set point is shown
in the display.
"ACTUAL TEMP"
Light
Lights when the Actual
Temperature is shown
in the display.
Temperature
Key
Press this key once
to view the Actual
Temperature in the
Display.
together with the Set
Point Key to allow the
changed. Changes
can only be made for
Unlock Key
Press this key
Set Point to be
60 seconds.
Up Arrow and Down
Arrow Keys
Press these keys to
adjust the Set Point up or
down. If the Set Point will
not change, refer to Set
Point Key and Unlock Key
in this section.
Service Key
Service use
only.
Set Point Key
Press this key
together with the
Unlock Key to allow
the Set Point to be
changed.
Changes can only be
made for 60 sec-
onds.
29
SECTION 3
OPERATION
IV. QUICK REFERENCE: TROUBLESHOOTING
SYMPTOMPROBLEMSOLUTION
light is lit, food product is
undercooked
Oven will not
turn on at all
Oven shuts down shortly
after it is turned on
appears in display,
oven is not heating
The oven temperature exceeded 650°F (343°C), and
the burner was automatically shut down.
Electrical power may not be
reaching the oven, or the
controls may be set incorrectly.
The gas burner did not light
within 90 seconds of turning the "HEAT" (
to the “ON” ("I") position.
This automatically engages a safety lockout
mode.
The oven did not reach
200°F (93°C) within 15 minutes of startup, and the oven
has stopped heating.
) Switch
•Follow the procedures under Daily Shutdown Procedures in
this section to shut down the oven. Contact your Middleby
Marshall Authorized Service Agent to determine and correct the
cause of the condition to prevent damage to the oven.
•Check that the circuit breaker/fused disconnect is turned on.
•Check that the "BLOWER"
position. The burner cannot engage until the blowers are in
operation.
•Turn the "HEAT" (
()switches to the "OFF" ("O") position.
•Wait for AT LEAST FIVE MINUTES before restarting the oven.
•Repeat the Daily Startup procedure.
•Turn the "HEAT" (), "BLOWER" (), and "CONVEYOR"
()switches to the "OFF" ("O") position.
•Wait for AT LEAST FIVE MINUTES before restarting the oven.
•Repeat the Daily Startup procedure.
() Switch is in the “ON” ("I")
), "BLOWER" (), and "CONVEYOR"
Oven will not heat
Oven is operating, but
little or no air is blowing
from air fingers
Conveyor moves with a
jerky motion, or will not
move at all
Food products are
overcooked or
undercooked.
Controls may be set incorrectly.
Air fingers may have been
reassembled incorrectly
after cleaning.
Conveyor may be jammed
on an object in the oven, or
conveyor belt or drive chain
tension may be incorrect.
Controls may be set incorrectly.
•Check that the Set Point is correctly set.
•Check that both the "BLOWER"
are in the “ON” ("I") position.
•If the oven still will not heat,turn the "HEAT" (), "BLOWER"
(), and "CONVEYOR" ()switches to the "OFF" ("O")
position.
•Wait for AT LEAST FIVE MINUTES before restarting the oven.
•Repeat the Daily Startup procedure. Check that the Set Point
is above 200°F (93°C).
•Turn the oven to the “OFF” or “O” position, and allow it to cool.
Disconnect electrical power to the oven.
•Refer to Section 4, Maintenance, for instructions on reassembling the air fingers.
•Turn the oven to the “OFF” or “O” position, and allow it to cool.
Disconnect electrical power to the oven.
•Check if the conveyor is blocked by an object inside the oven.
•Refer to Section 4,
the conveyor and drive chain tension.
•Check that the set temperature and bake time settings are
correct.
Maintenance, for instructions on checking
() and "HEAT" () Switches
IF THESE STEPS FAIL TO RESOLVE THE PROBLEM, CONTACT YOUR LOCAL MIDDLEBY MARSHALL
AUTHORIZED SERVICE AGENT. A SERVICE AGENCY DIRECTORY IS SUPPLIED WITH YOUR OVEN.
30
SECTION 4
MAINTENANCE
WARNING
Possibility of injury from rotating parts and electrical
shock exist in this oven. Turn off and lockout or tagout
electrical supply to oven(s) before attempting to
disassemble, clean or service oven(s). Never disas-
semble or clean the oven with the blower switch or any
other part of the oven turned on.
WARNING
Before performing any maintenance work or cleaning,
turn main power switch off.
SECTION 4
MAINTENANCE
CAUTION
When cleaning do not use any abrasive cleaning
materials or water spray, wipe clean only. Never use a
water hose or pressurized steam cleaning equipment
when cleaning this oven.
NOTICE
If the oven is to be removed from its installed location
for servicing, perform the following procedure:
1. Switch off the oven and allow it to cool. Do NOT
service the oven while it is warm.
2. Shut off main manual gas valve and disconnect
gas connector from oven.
3. Turn off main circuit breakers and disconnect
connector from oven.
4. Turn the adjustable legs to put weight on the
casters.
5. Move oven to desired location for servicing.
6. When servicing is complete, move oven to original
location.
7. Adjust legs to level oven and take weight off
casters.
8. Connect electrical and gas connectors to oven.
9. Turn on manual gas valve.
10. Turn on main circuit breakers.
11. Follow normal startup instructions.
31
SECTION 4
MAINTENANCE
I. MAINTENANCE - DAILY
A. Exterior
Everyday you should clean the outside of the oven with a
soft cloth and mild detergent.
WARNING
Never use a water hose or pressurized steam
cleaning equipment when cleaning the oven.
B. Cooling Fan
1. TWO COOLING FAN GRILLES AT THE REAR OF
EACH OVEN CONTROL COMPARTMENT MUST BE
CLEANED DAILY - Clean grilles with a stiff nylon type
brush.
2. Check the air intake of the cooling fan daily. The best
time to check is right after starting the oven.
IMPORTANT NOTE
D. Crumb Pans (Figure 4-2)
Remove and clean the crumb pan at each end of the oven.
Each crumb pan can be removed by sliding it out, as
shown in Figure 4-2. Reinstall the crumb pans after
cleaning.
E. Window
The window can be cleaned daily while it is in place.
Vent Grille
Cooling Fan Grille
The cooling fan operates when the blower switch
is turned to “ON” (“I”). It must operate to keep the
electrical control cabinet below 140°F (60°C).
WARNING
IF FAN BLADE IS NOT ROTATING, BROKEN,
OR FAN ASSEMBLY IS MISSING FROM MAIN
BLOWER MOTOR SHAFT, DO NOT OPERATE
OVEN. REPLACE COOLING FAN BLADE
BEFORE OPERATING OVEN. Serious damage
could be done to the burner blower motor and/or
solid-state electrical components if oven is
operated while cooling fan is not running or vent
grille is plugged.
3. Using a stiff nylon brush clean control compartment
vent grille. Hot air from control compartment exits from this
grille.
C. Conveyor Belt (Figure 4-2)
Cooling Fan Grille
Figure 4-1. Oven Cooling Fans
Everyday, just after starting the oven, stand at the
unloading end of the conveyor, and with a brush, remove
food particles (crumbs, etc.) clinging to the conveyor belt,
brushing them into the crumb pan.
Figure 4-2. Conveyor Belt and
Crumb Pan Cleaning
32
SECTION 4
MAINTENANCE
II. MAINTENANCE - MONTHLY
When cleaning your Series PS540 Oven note the
following:
PRECAUTIONS-
1. Do not use excessive water or saturation of oven
insulation will occur.
2. Do not use a caustic oven cleaner or the aluminized
finger manifold surfaces will be severely damaged.
When cleaning your oven, first remove all heavy debris
with a vacuum cleaner. Use a damp cloth for light cleaning.
For heavier cleaning of baked on grease and carbon
deposits use a non-caustic cleaner that will not react with
the aluminized finger manifold surfaces.
You can order non-caustic cleaner from your local authorized Middleby Marshall Parts Distributor in the quantities
listed below:
Part #Quantity
27170-0244Case of Quarts (6)
27170-0246Case of Gallons (4)
A. Removing Conveyor From Oven For Cleaning
1. Remove crumb pans as shown in Figure 4-2.
2. Remove upper and lower end plugs from each end of
oven by removing the two wing screws from each end plug.
3. Remove the conveyor end stop and the conveyor rear
stop (Figure 4-3).
Figure 4-3.
33
SECTION 4
MAINTENANCE
4. Remove conveyor drive chain cover as shown.
5. Remove tension from drive chain by lifting and pushing
the conveyor slightly into the oven. Remove drive chain
from conveyor drive sprocket as shown.
NOTE: The split belt conveyor assembly can only be
removed from the drive end of the oven.
6. Begin sliding conveyor out of the oven as shown.
Figure 4-4.
Figure 4-5.
Figure 4-7.
7. Continue sliding the conveyor completely out of the
oven, fold it in half and then place it to the side for cleaning.
Be careful not to bump drive sprocket while handling
conveyor or damage may result to drive shaft.
Figure 4-8.
CAUTION
Figure 4-6.
Be careful not to bump the drive sprocket while
handling the conveyor, to avoid damaging the
drive shaft.
34
B. Air Fingers Disassembly For Cleaning
1. As the air fingers are removed use a felt pen to mark all
parts of the fingers. This includes the finger manifold, inner
plate and the outer plate (refer to Figure 1-9). If a blank or
choke plate is used, mark that plate also. Fingers are
marked in the order shown; as viewed from the front of the
oven. (The marks for an upper oven should be preceded
with a “U”, example UB1, UT2, etc.)
T1T2T3T4
B1B2B3B4
Standard Fingers
2. Slide blank plates straight out.
SECTION 4
MAINTENANCE
Figure 4-10.
4. With air fingers out, place them in an upright position to
remove the outer plate.
Figure 4-9.
3. Remove air fingers.
NOTE: Some oven users require a custom finger arrangement where the quantity of air fingers may vary.
You can remove top and bottom fingers and blank plates
from each or either end. It is highly recommended that
each finger be marked before removing so it is placed in
exactly the same position when reassembled
(refer to step 1).
5. Gently step o the lip of the finger and pull the outer plate
off.
Remove the air fingers, pull the finger at the back side - pull
straight out.
Figure 4-11.
35
SECTION 4
MAINTENANCE
6. To remove the inner plate, pull the plate out and then up.
Figure 4-12.
7. The outer finger plate is stainless and may be cleaned
by either soaking in a hot, strong detergent solution or
using a caustic cleaner. The conveyor belt can also be
cleaned in the same way.
1. Remove the window by opening the window and unscrewing the window knobs from each end.
Figure 4-15.
2. Push the window all the way inside the oven, making
sure it is clear of the frame. Now, turn the window sideways
while inside the oven and then remove it. This will avoid
breaking the window.
Figure 4-13. Standard Lower Finger
Figure 4-14. Standard Upper Finger
C. Cleaning the Window
The window can be cleaned in place. If it needs a thorough
cleaning it may have to be removed.
Figure 4-16.
D. Reassembly of Air Fingers
1. Air fingers are made up of one inner plate, one outer
plate and the finger housing manifold. Be sure to match up
the markings (T1, T2, T3, etc.) on all the parts of the air
fingers as you are reassembling.
Figure 4-17.
36
2. Reassemble the inner plate. Keep your fingers clear so
you won’t pinch them. The inner plate of a finger will only
go in one way because of its design.
3. Replace the outer plate by placing your hands flat on
the top of the plate and pushing down. Keep your fingers
clear so you won’t pinch them.
SECTION 4
MAINTENANCE
Figure 4-19.
IMPORTANT: Only M6 Fingers fit in the bottom
row. All M3 and M1 finger cover plates have
extended lips at front. This extended lip will not
allow these fingers to be installed in the bottom row.
Figure 4-18.
4. Replace the air fingers by pushing in at the back side.
Remember to replace them according to the numbers
marked on them when they were removed. They must go
back in the same way they came out.
Extended Lip
Flange of
Finger Manifold
IMPORTANT: When inserting fingers the tab on
the outer plate must be in the groove as shown in
Figure 4-20. There is a blocking tab on the outside
of the groove which will prevent inserting the
finger in the groove if the outer plate is moved
away from the flange of the finger manifold.
Tab on
Outer Plate
Figure 4-20.
37
Tab on
Outer Plate
SECTION 4
MAINTENANCE
5. Install fingers and blank plates correctly with edges
interlocked and no space between edges.
Top Finger
Tab on Outer Plate of Finger
Located in Groove
Top Finger
Incorrect - Too
Much Space
Blank Plate
Incorrect - Too
Much Space
Blank Plate
Tab on Outer Plate of Finger
Located in Groove
Top Finger
Tab on Outer Plate of Finger
Located in Groove
Correct Edges Overlap
Completely
Blank Plate
Figure 4-21.
38
E. Reinstall End Plugs
1. Reinstall lower end plug. Be sure to tighten two wing
screws on the end plug.
2. Reinstall conveyor.
3. Reinstall upper end plug. Be sure to tighten two wing
screws on the end plug.
SECTION 4
MAINTENANCE
Figure 4-22.
Figure 4-23.
39
SECTION 4
MAINTENANCE
F. Conveyor Reassembly Into Oven
1. Lift conveyor and position it in oven as shown.
NOTE: Conveyor assembly may be inserted into either
end of oven. If it is to be installed from the non-drive end
of the oven the drive sprocket assembly must be removed
as shown in conveyor disassembly section.
NOTE: Split belt conveyors can only be inserted from the
drive end of the oven.
G. Checking Conveyor Belt Tension
WARNING
Oven conveyor belt must be cool when adjusting
belt. Do not adjust belt if HOT.
1. With the conveyor assembly in the oven, stand at one
end of conveyor and check tension by lifting the conveyor
belt at the center of the oven chamber opening. The belt
should not lift higher that 3″ to 4″ (75mm to 102mm).
2. Adjust conveyor belt tension screws (located on left
end of oven) for the 3″ to 4″ (75mm to 102mm) deflection
as shown in Figure 4-26. If there is proper tension, proceed
to “J. Attaching Drive Chain”. If belt is still too loose,
continue to step 3 below.
3. If conveyor belt is still not under proper tension, an
entire link must be removed. Use the following procedure
“H. Conveyor Belt Link Removal” to remove a link. If
conveyor belt is under proper tension proceed directly to
“J. Attaching Drive Chain”.
Figure 4-24.
2. Reinstall the conveyor rear stop. Reinstall the conveyor end stop.
Conveyor Rear Stop
Middleby
Conveyor End Stop
Marshall
Figure 4-25.
Figure 4-26.
40
SECTION 4
MAINTENANCE
H. Conveyor Belt Link Removal
1. Using long nose pliers, an entire link can be removed
with the conveyor assembly either in or out of the oven.
Position master links at end of conveyor as shown in
Figure 4-27.
Master
Links
Figure 4-27.
4. Unhook the link to be removed.
5. Pull up on the belt link section and remove. Do not
discard the link removed as it may be used for making
spare master links.
NOTE: If a section of the conveyor belt is being replaced
it should be done now. Remove the links that need
replacing and use the section of conveyor belt furnished in
your installation kit to replace them.
2. Using long nose pliers, unhook master links at left end
of conveyor as shown in Figure 4-28.
Figure 4-28.
3. Remove the outside master links on the right and left
sides of the conveyor belt as shown in Figure 4-29.
Figure 4-30.
NOTE: Before connecting the inside master links, notice
that these links have a correct position (Figure 4-31). The
link at the right is in the correct (horns up) position for
inserting into the conveyor belt. The horns facing down are
in the incorrect position.
Correct
Position
Incorrect
Position
Figure 4-31.
Figure 4-29.
41
SECTION 4
MAINTENANCE
6. Reconnect the inside master links (Figure 4-32.)
Figure 4-32.
NOTE: The outside master links have right and left sides
to them. The right edge master link has an open hook
facing you as shown in Figure 4-33. This will match up with
the outer edges of the conveyor belt. Remember this hook
travels backwards on the conveyor.
Direction of travel
I. Replacing Conveyor Belt
If a section of the conveyor belt needs replacing it can be
done with the conveyor assembly either in or out of the
oven. The section of the conveyor belt furnished with the
oven in the installation kit may then be used to replace a
section. Follow the preceding procedure “H. Conveyor belt
link removal” which outlines the disassembly procedure.
J. Attaching Drive Chain
1. If drive sprocket assembly was removed reassemble it
into the conveyor drive shaft. Be sure flat on end of drive
shaft aligns with set screw in conveyor shaft collar. Once
in place tighten 3/32″ set screw.
2. Lift conveyor and install drive chain to conveyor drive
sprocket and motor sprocket.
Figure 4-33.
7. Reconnect the outside master links.
8. Replace all parts removed from the oven.
Figure 4-34.
Figure 4-35.
3. The angle plate located on the underside of the conveyor must be against the lower end plug. This is true on
both sides of oven.
Crumb Pan
Mounting
Bracket
Lower End Plug
Figure 4-36.
42
SECTION 4
a
MAINTENANCE
4. Reassemble conveyor drive chain cover and then
reassemble the bottom cover to the drive chain cover.
Install both upper end plugs.
Figure 4-37.
III. MAINTENANCE - EVERY 3 MONTHS
WARNING
Shut OFF all electrical power and lock/tag out the
switch before attempting maintenance work.
Shut OFF gas supply to oven.
NOTE: It is recommended that the 3-month maintenance be performed by an authorized Middleby Marshall
technician.
A.Cleaning the Blower/Fan Motor
To gain access to the blower/fan motor, open the control
cabinet door by removing the three screws. Clean the
motor, burner blower motor, the conveyor drive motor and
the surrounding area, using either compressed air or CO2.
Thoroughly blow out the motor compartment and vents
inside the motor (Figure 4-38). Failure to do this can cause
premature failure of blower fan motor.
Fan Motor-•
Blow Out•
In This Are
Conveyor
D.C. Motor
Burner•
Blower•
Motor
CAUTION
Not cleaning the blower/fan motor properly can
cause premature failure.
Figure 4-38.
43
SECTION 4
MAINTENANCE
B. Electrical Terminals
Open the control cabinet door by removing the three
screws from the control cabinet door. Tighten all electrical
control terminal screws including the electrical contactor
terminal screws as shown in Figure 4-39.
CAUTION
Overtightening the belt will cause premature bearing
failure and possible vibration problems. A spare
belt is located inside the control compartment on
the rear wall.
3. When replacing the belt, loosen the tension adjustment
bolts (Figure 4-42) on the motor mounting bracket. Next,
pull back on the motor. Retighten adjustment bolts. Do not
overtighten because the fan bearings may be damaged.
Figure 4-39.
C. Ventilation
Check that the air circulation throughout the oven is not
blocked and is working properly.
D. Checking the Blower/Fan Belt
1. Check the main blower/fan belt for proper tension and
wear. To gain access,loosen the six screws (Figure 4-40)
of the rear shroud and lift shroud cover up and off.
2. The fan belt should deflect no less than 1″ (25mm) at
the center (Figure 4-41) and have no cracks or excessive
wear.
Figure 4-41.
Figure 4-42.
Figure 4-40.
44
SECTION 4
MAINTENANCE
E. Blower Fan Shaft Bearing Lubrication
CAUTION
Over-greasing damages the bearing seals and
accelerates grease loss, which shortens bearing
life. Wipe off any excess grease on and around
the bearing. Reinstall the rear shroud to allow the
oven to operate
Grease the two (2) main blower fan shaft bearings (Figure
4-43), using a special grease (MM P/N 17110-0015 lithiumbase, high-temperature grease). ONLY ONE STROKE of
a grease gun is required for each bearing.
3. Remove the conveyor adjustment bolts to allow the
idler brackets to swing free.
Figure 4-44.
4. Drop the idler shaft assembly clear of the frame through
the front frame slot.
Figure 4-43.
Upon completing the fan belt check (or replacement) and
the bearing lubrication, reinstall the rear shroud, fastening
it with six screws of the rear shroud.
F. Split-belt Conveyor Shaft Cleaning
It is very important that the split-belt conveyor drive and
idler shafts are removed from the conveyor frame for
cleaning and lubrication.
CAUTION
Use a turbine oil or light machine oil. DO NOT
USE WD40 or similar product. These oils
evaporate and cause the shafts to seize.
1. Perform the conveyor removal steps described in
Monthly Maintenance, paragraph “A”. After the conveyor
is removed, lay it on a flat surface.
2. Remove the two conveyor belts by disassembling the
conveyor master links, as described in Monthly Maintenance, paragraph “H”. Then, remove the two conveyor
belts by rolling them up.
Figure 4-45.
5. Pull the front and rear shafts apart and apply oil to both
the extended shaft and the interior of the hollow shaft.
Using a rag, wipe oil off parts. Repeat until shafts are
clean. Apply more oil to shafts then reassemble.
Figure 4-46.
45
SECTION 4
MAINTENANCE
6. Make sure bronze washer is in between the two halves.
Figure 4-47.
7. Place the idler shaft assembly back into place and
reinstall the adjustment screws.
9. Loosen the split locking collar.
Figure 4-50.
10. Remove drive shafts by sliding to right then lifting the
left side. Follow cleaning and lubricating procedures outlined in Steps 4-6.
Figure 4-48.
8. Loosen the set screw on each conveyor drive sprocket
and remove sprockets.
Figure 4-49.
Figure 4-51.
11. Reassemble conveyor drive shafts into frame, making sure nylon spacer is in place.
Figure 4-52.
46
12. Slide shaft assembly to right side, holding assembly
in place. Slide split locking collar to the left side and
tighten.
13. Slide rear conveyor drive sprocket onto shaft. Tighten
the set screw of this drive sprocket until it extends into the
hole of the hollow shaft. It should NOT touch the inner,
solid shaft. Check to see that only the rear shaft moves
when the sprocket is turned. If both shafts move, you have
tightened the set screw too tight. Loosen the set screw
until only the rear shaft moves when the sprocket is
turning.
14. Insert adaptor bushing into remaining drive sprocket
then place onto shaft. Make sure nylon spacer is in place.
Tighten set screw making sure screw goes through slot in
adaptor bushing and locks onto shaft.
15. Thread conveyor belts back onto frame making sure
the links will be traveling in the proper direction.
16. Follow conveyor reassembly instructions in Monthly
Maintenance Paragraph “F”.
SECTION 4
MAINTENANCE
Figure 4-53.
NOTE: It is recommended that the 6 Month Maintenance
schedule be performed by a Middleby Marshall authorized
service technician.
IV. MAINTENANCE - EVERY 6 MONTHS
A. Check brushes on D.C. conveyor motor, when worn to
less than 1/10″ (2.4mm), replace the brushes.
B. Clean and inspect the burner nozzle and electrode
assembly. Also check your oven venting system.
C. Check conveyor shaft bushings and spacers. Replace
them if they are worn. See Figure 6-5, Conveyor Exploded
Drawing, items 15, 30 and 31 or Figure 6-6, Split Belt
Conveyor, items 19, 23, 31, 35 and 36.
IMPORTANT NOTICES:
• The installation, startup and changes required
when changing from one gas type to another can be
performed only by an authorized service technician.
CANADIAN REGULATIONS PROHIBIT
CHANGING AN OVEN’S OPERATION FROM
ONE GAS TO ANOTHER.
Figure 4-54.
Figure 4-55.
• Installation of replacement parts requiring access
to the interior of the oven is permitted only by an
authorized service technician.
• If there are any problems with the operation of the
oven, the authorized service technician must be
called.
• It is suggested to obtain a service contract with a
manufacturer’s authorized service technician.
Figure 4-56.
47
SECTION 4
MAINTENANCE
KEY SPARE PARTS KIT
An oven can be purchased with a Key Spare Parts Kit
(Figure 4-56). (The kit can be purchased when the oven is
ordered, or later, from a Middleby Marshall Authorized
Parts Distributor). The kit contains many of the crucial
PS540-SERIES GAS OVEN KEY SPARE PARTS (Figure 4-56)
ITEMPART NO.ENGLISH DESCRIPTIONQUANTITY
147321Temperature Controller1
244687Blower/Fan Motor1
347797Conveyor Drive Motor1
460542Conveyor Speed Control1
533812-3Thermocouple1
660679Assy, Valve Gas Module1
750275Burner & Motor Assembly1
850239Ignition Control Module (kit)1
parts that can reduce serious downtime and loss of
production, if a failure occurs.
Replacement parts for this kit can be purchased from your
Middleby Marshall Authorized Parts Distributor.
Figure 4-56. Key Spare Parts
48
SECTION 5
TROUBLESHOOTING
SECTION 5
TROUBLESHOOTING
PROBLEM:
PRODUCTS ARE OVERCOOKED
OR UNDERCOOKED
Check for correct
setting of conveyor
speed control.
Set the conveyor speed
control at correct setting.
Verify the food
preparation process.
If products still cook incorrectly,
call your Middleby Marshall
Service Agency.
setting on tempera-
Check for correct
ture controller.
Turn temperature
control to correct
setting.
PROBLEM:
OVEN BLOWER AND CONVEYOR OPER-
ATE, YET THE OVEN IS NOT HEATING
Reset the temperature controller
to a new setting (above 200°F),
after turning the BLOWER switch
to off for 30 seconds.
Start the oven again. If the oven still does not
heat, call your Middleby Marshall Service Agency.
PROBLEM:
CONVEYOR WILL NOT HOLD PROPER
SPEED OR WILL NOT RUN AT ALL
Check whether the conveyor is
jammed on something in oven.
PROBLEM:
OVEN DOES NOT HEAT
Check to see if both BLOWER
switch and HEAT switch are in
the “ON” or “I” position.
If oven does not heat, call your
Middleby Marshall Service Agency.
PROBLEM:
BLOWER MOTOR IS RUNNING, YET LITTLE
OR NO AIR BLOWS FROM AIR FINGERS
Air fingers reassembled incorrectly,
after cleaning.
Assemble air fingers correctly, after cleaning.
Refer to Section 4 procedure, or call your
Middleby Marshall Service Agency.
Check for proper tension of conveyor drive
chain and conveyor belt. Refer to Section 4 for
correct procedure.
Check that the conveyor
drive sprocket is tight.
If conveyor still does not run correctly, contact
your Middleby Marshall Service Agency.
PROBLEM:
OVEN DOES NOT TURN ON WHEN ITS
SWITCHES ARE TURNED ON
Check that all electric supply switches are set to
the “ON” or “I” position. Then, start the oven.
If oven still will not start, contact your Middleby
Marshall Service Agency.
49
SECTION 5
TROUBLESHOOTING
NOTES
50
SECTION 6 - PARTS LIST
SECTION 6
PARTS LIST
ENGLISH
51
SECTION 6
PARTS LIST
ENGLISH
52
SECTION 6
PARTS LIST
ENGLISH
OVEN PANELS, WINDOW AND LEGS
1249947UPPER END PLUG ASSEMBLY
2249946LOWER END PLUG ASSEMBLY
3836452WING NUT, PLASTIC 1/4-20
4845449END PLUG MOUNTING PLATE ASSEMBLY
51 621296-0005SCREW, HEX WSHHD12-14 × 3/4″, SS BSD
15133812-3THERMOCOUPLE, TYPE “J” SHIELDED 9.50 × 60″
65
SECTION 6
PARTS LIST
ENGLISH
NOTES
66
ELECTRICAL SCHEMATICS
SECTION 7
ELECTRICAL SCHEMATICS
SECTION 7
50141H
67
Wiring Diagram, G208-240 50/60, 1PH 3W PS540
SECTION 7
ELECTRICAL SCHEMATICS
50141H
68
Wiring Diagram, G208-240 50/60, 1PH 3W PS540
NOTES
SECTION 7
ELECTRICAL SCHEMATICS
69
SECTION 7
ELECTRICAL SCHEMATICS
NOTES
70
NOTES
WARNING
Improper installation, adjustment, alteration, service or maintenance
can cause property damage, injury or death. Read the installation,
operating and maintenance instructions thoroughly before
installing or servicing this equipment.
NOTICE
During the warranty period, ALL parts replacement and servicing should be performed by
your Middleby Marshall Authorized Service Agent. Service that is performed by parties
other than your Middleby Marshall Authorized Service Agent may void your warranty.
NOTICE
Using any parts other than genuine Middleby Marshall factory manufactured parts relieves
the manufacturer of all warranty and liability.
NOTICE
Middleby Marshall reserves the right to change specifications at any time.
Middleby is proud to support the Commercial Food Equipment
Service Association (CFESA). We recognize and applaud
CFESA's ongoing efforts to improve the quality of technical
service in the industry.
Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • USA • (847)741-3300 • FAX (847)741-4406
24-Hour Service Hotline: 1-(800)-238-8444
www.middleby.com
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