Middleby Marshall Oven PS536 Installation Manual
PS536 Gas and Electric
Europe
ENGLISH/German/
French/Spanish
P/N 46525
Rev. B V1 9/01
page 1
ENGLISH
Seite 35
DEUTSCH
PS536 Gas and Electric Ovens
Models:
PS536
OWNER'S OPERATING AND
INSTALLATION MANUAL
for European export ovens
Single Oven Double Oven Triple Oven
Rated Heat Input, Natural Gas 14.6kW-hr. Natural Gas 2x14.6kW-hr. Natural Gas 3x14.6kW-hr.
Gas Ovens Propane 13.2 kW-hr. Propane 2x13.2 kW-hr. Propane 3x13.2 kW-hr.
Rated Heat Input, 17kW 2x17kW 3x17kW
Electric Ovens
Heating Zones 1 controlled 2 controlled 3 controlled
heat zone heat zones heat zones
Combinations:
Single Oven
Double Oven (Two-Stack)
Triple Oven (Three-Stack)
page 69
FRANÇAIS
página 103
ESPAÑOL
© 2001 Middleby Marshall, Inc.
is a registered trademark of Middleby Marshall, Inc. All rights reserved.
Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin, IL 60120 (847)741-3300 FAX (847)741-4406
1
NOTICE:
Owner's Operating and Installation Manual should be given to the user. The operator of the oven should
This
be familiar with the functions and operation of the oven.
This manual must be kept in a prominent, easily reachable location near the oven.
ENGLISH
Gas ovens are designed for use with EITHER natural gas OR liquid propane gas, as specified on the serial plate.
Where permitted by local and national codes, the oven can be converted from natural gas to propane operation,
or from propane to natural gas operation. This conversion is described in the Installation section of this Manual.
The conversion requires the installation of the appropriate Middleby Marshall Gas Conversion Kit.
It is suggested to obtain a service contract with a Middleby Marshall Authorized Service Agent.
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.
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors or 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,
operating and maintenance instructions thoroughly before installing
or servicing this equipment.
IMPORTANT
An electrical wiring diagram for the oven is located inside the machinery
compartment.
IMPORTANT
It is the customer's responsibility to report any concealed or non-concealed damage
to the freight company. Retain all shipping materials until it is certain that the
equipment has not suffered concealed shipping damage.
NOTICE: CONTACT YOUR MIDDLEBY MARSHALL AUTHORIZED SERVICE AGENT TO PERFORM MAINTENANCE
AND REPAIRS. AN AUTHORIZED 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.
NOTICE: The equipment warranty is not valid unless the oven is installed, started and demonstrated under the supervision
of a factory certified installer.
Retain This Manual For Future Reference
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
2
TABLE OF CONTENTS
page page
SECTION 1 - DESCRIPTION ................................................... 4
V. GAS SUPPLY .......................................................... 17
I. OVEN USES ............................................................. 4
II. OVEN COMPONENTS ............................................. 4
A. Window ............................................................. 4
B. Conveyor Exit Tray ............................................ 4
C. Eyebrows .......................................................... 4
D. End Plugs ......................................................... 4
E. Control Panel .................................................... 4
F. Machinery Compartment Access Panel .......... 4
G. Serial Plate ....................................................... 4
H. Conveyor Drive Motor ....................................... 4
I. Crumb Pans ..................................................... 4
J. Conveyor ........................................................... 4
K. Heating Elements ............................................ 4
L. Blow ers ............................................................. 4
M. Air Fingers ........................................................ 4
III. OVEN SPECIFICATIONS ......................................... 4
A. Dimensions ...................................................... 4
B. General Specifications ..................................... 4
C. Electrical Specifications for Electric Ovens ..... 5
D. Electrical Specifications for Gas Ovens .......... 5
E. Gas Orifice and Pressure Specifications........ 5
A. Connection ...................................................... 17
B. Preparation for Use with Various Gases ....... 18
C. Replacing the Gas Orifices ............................. 18
D. Checking the Gas Supply (Inlet) Pressure .... 19
E. Adjusting the Orifice (Manifold) Pressure
and Heat Input ................................................. 19
SECTION 3 - OPERATION ..................................................... 21
I. LOCATION AND DESCRIPTION OF CONTROLS . 21
A. BLOWER (
B. CONVEYOR (
C. Conveyor Speed Controller ............................. 21
D. RESET ( ) Switch ...................................... 21
E. Digital Temperature Controller .......................21
F. Machinery Cpt. Access Panel Safety Switch .. 21
II. NORMAL OPERATION, STEP-BY-STEP ................22
A. Daily Startup Procedure .................................. 22
B. Daily Shutdown Procedure ............................. 23
III. QUICK REFERENCE: DIGITAL TEMPERATURE
CONTROLLERS ..................................................... 24
IV. QUICK REFERENCE: TROUBLESHOOTING ....... 26
) Switch ......................................21
) Switch ............................... 21
ENGLISH
SECTION 2 - INSTALLATION .................................................. 6
I. INSTALLATION KIT .................................................. 7
II. VENTILATION SYSTEM ........................................... 8
A. Requirements .................................................. 8
B. Recommendations .......................................... 8
C. Other Ventilation Concerns .............................. 8
III. ASSEMBLY ............................................................... 9
A. Base Pad Assembly ......................................... 9
B. Stacking ........................................................... 10
C. Conveyor Installation ....................................... 1 1
IV. ELECTRICAL SUPPLY ........................................... 16
A. Additional Information - Gas Ovens ................ 16
B. Additional Information - Electric Ovens .......... 16
C. Connection ...................................................... 16
SECTION 4 - MAINTENANCE ................................................. 27
I. MAINTENANCE - DAILY ..........................................27
II. MAINTENANCE - MONTHLY .................................. 28
III. MAINTENANCE - EVERY 3 MONTHS .................... 28
IV. MAINTENANCE - EVERY 6 MONTHS .................... 32
V. KEY SPARE PARTS KIT ......................................... 3 2
SECTION 5 - ELECTRICAL WIRING DIAGRAMS ................... 33
I. WIRING DIAGRAM, PS536 ELECTRIC OVEN,
380V, 50 Hz, 3 Ph ................................................... 3 3
II. WIRING DIAGRAM, PS536 GAS OVEN,
220-230V, 50 Hz, 1 Ph ............................................ 34
3
SECTION 1 - DESCRIPTION
I. OVEN USES
PS536 Ovens can be used to bake and/or cook a wide
variety of food products, such as pizza, pizza-type products,
cookies, sandwiches and others.
ENGLISH
II. OVEN COMPONENTS - see Figure 1-1.
A. Window (on ovens so equipped): Allows the user to see
and access food products inside the baking chamber.
B. Conveyor Exit Tray: Prevents food products from falling off
the end of the moving conveyor.
C. Eyebrows (on ovens so equipped): Can be adjusted to
various heights to prevent heat loss into the environment.
D. End Plugs: Allow access to the oven's interior.
E. Control Panel: Location of the operating controls for the
oven. Refer to Section 3,
F. Machinery Compartment Access Panel: Allows access
to the oven's interior components. No user-servicable
parts are located inside the machinery compartment.
G. S e r i a l P l a t e : Provides specifications for the oven that affect
installation and operation. Refer to Section 2,
for details.
H. Conveyor Drive Motor: Moves the conveyor.
I. Crumb Pans: Catch crumbs and other material that drop
through the conveyor belt. One crumb pan is located
underneath each end of the conveyor.
J. Conveyor: Moves the food product through the oven.
Operation, for details.
Installation,
Not Shown:
K. Gas Burner (gas ovens) or Heating Elements (electric
ovens): Heat air, which is then projected to the air fingers
by the blowers.
L. Blowers: Fans that project hot air from the burner or
heating elements to the air fingers.
M. Air Fingers: Project streams of hot air onto the food
product.
Fig. 1-1 - Oven Components
B
A
EDC
G
H
I
J
F
Ovens with Ovens with Ovens with Ovens with
III. OVEN SPECIFICATIONS
Table 1-1: Dimensions
Overall Height: single oven w/standard 446mm legs 1105mm 1105mm 1105mm --
single oven w/custom 597mm legs -- 1256mm 1256mm --
double oven w/standard 446mm legs 1549mm 1549mm 1549mm - -
double oven w/custom 521mm legs -- 1624mm 1624mm 1624mm
triple oven w/standard 152mm legs 1702mm 1702mm 1702mm - -
Overall Depth: without optional front window 1010mm 1010mm 1010mm 1010mm
with optional front window 1092mm 1092mm 1092mm 1092mm
Overall Length: without exit tray installed 1422mm 1524mm 1537mm 1943mm
with exit tray installed -- 1734mm 1734mm 2140mm
Baking Chamber Length < - - - - - - - - - - - - - - - - - - 914mm - - - - - - - - - - - - - - - - - - >
Conveyor Width:Si ngle Be lt < - - - - - - - - - - - - - - - - - - 508mm - - - - - - - - - - - - - - - - - - >
Split Belt < - - - - - - - - - - - - - - - - - 2 x 241mm - - - - - - - - - - - - - - - - - >
Conveyor Length 1422mm 1524mm 1524mm 1930mm
Recommended Minimum Clearances:
Rear of oven to wall < - - - - - - - - - - - - - - - - - - 76mm - - - - - - - - - - - - - - - - - - >
Control end of conveyor to wall < - - - - - - - - - - - - - - - - - - 457mm - - - - - - - - - - - - - - - - - - >
Non-control end of conveyor to wall < - - - - - - - - - - - - - - - - - - 76mm - - - - - - - - - - - - - - - - - - >
* Refer to Figures 2-9 and 2-10 in the Installation section for illustrations of Type 1 and Type 2 conveyors.
1422mm-long 1524mm-long 1524mm-long 1930mm-long
Type 1 conveyor* Type 1 conveyor* Type 2 conveyor* Type 2 conveyor*
(custom) (standard) (standard) (custom)
Table 1-2: General specifications (per oven cavity)
Weight 182kg
Rated Heat Input: Gas Ovens, Natural Gas 14.6kW-hr.
Gas Ovens, Propane 13.2kW-hr.
Electric Ovens 17kW
Operating Temperature 93-316°C
Warmup Time 25 minutes
4
SECTION 1 - DESCRIPTION
Table 1-3: Electrical specifications for electric ovens (per oven cavity)
Main Blower Control Current kW
Voltage Circuit Voltage Phase Freq. Draw Rati ng Poles Wires
230V 120V conv. speed control, 3 Ph 50 Hz 25A 17.0 kW at 380V 4 Pole 5 Wire (3 hot,
drive motor, contactor, 1 neutral, 1 ground)
& temp. control; all others 230V
IMPORTANT: Additional electrical information is provided on the oven's serial plate, and on the wiring diagram inside the
machinery compartment.
CAUTION: The current draw shown in the chart above is an average value for normal operation. The initial amperage draw on
oven startup may exceed the listed value.
Table 1-4: Electrical specifications for gas ovens (per oven cavity)
Main Blower Control Circuit Current draw Poles Wires
Vo lta g e Vo lta g e Phase Freq (avg.) *
220-230V 120V conveyor speed controller 1 Ph 50Hz 4.0-4.6A * 2 Pole 3 Wire (1 hot,
(with transformer); 1 neutral,
all other control circuits 230V 1 ground)
IMPORTANT: Additional electrical information is provided on the oven's serial plate, and on the wiring diagram inside the
machinery compartment.
CAUTION: The current draw shown in the chart above is an average value for normal operation. The initial amperage draw on
oven startup may exceed the listed value.
ENGLISH
Table 1-5: Gas orifice and pressure specifications (per oven cavity)
Supply (Inlet) Pressure
Gas Ori fice DK,FI,GB NL DE BE,FR FI,DE,NL ES,GB (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 14.6
mm mbar mbar mbar mbar kW-hr.
G25 2.3749 -- 25 - - -- -- -- 16.19 14.6
mm mbar mbar kW-hr.
G30 2.3749 -- -- -- -- 29 or 50 28, 30, 37, 26.15 13.2
mm mbar or 50 mbar mbar kW-hr.
IT,PT,ES,SE,
I
2H
I
2L
I
2E
I
2E+
I
3B/P
I
3+
Pressure Input
5
WARNING - For gas ovens, after any conversions, readjustments, or service work on the oven:
ENGLISH
For electric ovens, after any conversions, readjustments, or service work on the oven, check that the
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 Description section of
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
SECTION 2 - INSTALLATION
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
ventilation system (if so equipped) is in operation.
WARNING
Keep the appliance area free and clear of combustibles.
WARNING
this Manual.
WARNING
installed shall not affect the air supply to the oven.
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
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 the
oven installation. During the installation procedure, the casters MUST be removed, so that the oven can be
supported by the supplied 152mm adjustable legs.
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 supercede the require-
ments and guidelines provided in this manual.
6
SECTION 2 - INSTALLATION
Figure 2-1 - Installation Kit
3
7
1
2
8a 8b
13
12
11
6
17
9
16
5
4
1
10
14
I. INSTALLATION KIT - see Figure 2-1
Item Single Oven Double Oven Triple Oven Part No. Description
1 1 2 3 42882 Top panel
2 2 2 2 220352 Screw, pan head #10 x 1" (top panel - front)
3 2 2 2 3A80A8801 Screw, pan head #10 x 2" (top panel - rear)
4 -- 1 2 44837 Stacking panel
5 -- 1 2 44918 Insulation, stacking panel, pre-cut
6 -- 4 8 4111A8815 Screw, hex head #10-32 x 1/2" (stacking panels)
7 1 1 1 42893 Base pad
8a 4 4 - - 42890 445mm leg extension (standard), for single and double ovens
8b 4 -- - - 45329 597mm leg extension (custom), for single ovens
8c 4 4 -- 45360 521mm leg extension (custom), for single and double ovens
8b - - -- 4 44799 152mm leg extension (standard), for triple ovens
9 4 4 4 22450-0028 Leg, adjustable, 152mm
10 4 4 4 22290-0010 Caster, with flat plate (no brake)
11 32 32 32 220373 Hex bolt, 3/8"-16 x 1"
12 32 32 32 21416-0001 Flat washer, 3/8"
13 32 32 32 21422-0001 Lockwasher, 3/8"
14 1 1 1 46525 Owner's Operating Manual, PS536 Gas and Electric Ovens (European
15 1 1 1 1002040 Middleby Marshall Authorized Service Agency Listing
16 1 2 3 22361-0001 Gas hose (gas ovens only)
Optional components (available separately):
17 1 1 1 46393 Lower shelf
Qty. Qty. Qty.
NOTE: These casters are provided to allow the oven to be more easily
moved to the installation location, and are NOT suitable for use as part
of the oven installation. Refer to the notice on the preceding page.
Export models), English/German/French/Spanish
7
ENGLISH
15
SECTION 2 - INSTALLATION
II. VENTILATION SYSTEM
IMPORTANT
ENGLISH
Where national or local codes require the
installation of fire suppression equip-
ment or other supplementary equipment,
DO NOT mount the equipment directly to
the oven.
MOUNTING SUCH EQUIPMENT ON
THE OVEN MAY:
VOID AGENCY CERTIFICATIONS
RESTRICT SERVICE ACCESS
LEAD TO INCREASED SERVICE EX-
PENSES FOR THE OWNER
A. Requirements
CAUTION
Gas oven installations
ventilation system with electrical exhaust air sensing control.
A mechanically driven ventilation system is
RECOMMENDED for electric oven installations.
PROPER VENTILATION OF THE OVEN IS THE
RESPONSIBILITY OF THE OWNER.
REQUIRE a mechanically driven
STRONGLY
B. Recommendations
NOTE THAT THE HOOD DIMENSIONS SHOWN IN FIGURE 2-
RECOMMENDATIONS ONLY. LOCAL, NATIONAL AND
2 ARE
INTERNATIONAL CODES MUST BE FOLLOWED WHEN
INSTALLING THE VENTILATION SYSTEM. ANY APPLICABLE
CODES SUPERSEDE THE RECOMMENDATIONS SHOWN IN
THIS MANUAL.
The rate of air flow exhausted through the ventilation system
may vary depending on the oven configuration and hood design.
Consult the hood manufacturer or ventilation engineer for these
specifications.
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 heatrelated 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 (HVAC)
system. Through the HVAC system, the air can be temperaturecontrolled for summer and winter. Return air can also be
brought in directly from outside the building, but detrimental
effects can result from extreme seasonal hot and cold
temperatures from the outdoors.
NOTE: Return air from the mechanically driven system
blow at the opening of the baking chamber. Poor oven baking
performance will result.
C. Other ventilation concerns
Special locations, conditions, or problems may require the
services of a ventilation engineer or specialist.
Inadequate ventilation can inhibit oven performance.
It is recommended that the ventilation system and duct
work be checked at prevailing intervals as specified by the
hood manufacturer and/or HVAC engineer or specialist.
must not
51mm
minimum
305mm
minimum
Fig. 2-2 - Ventilation System
305mm
minimum
8
203mm
minimum
25mm
minimum
III. ASSEMBLY
A. Base Pad Assembly
1. Install the four leg extensions onto the base pad using the
3/8"-16x1" screws, 3/8" flat washers, and 3/8" lockwashers
supplied in the Base Pad Kit. See Figure 2-3. Check that
the finished sides of each leg extension face OUTWARDS.
2. If desired, position the optional lower shelf in place as
shown in Figure 2-3. Check that the lip on the shelf faces
DOWN. The shelf is available separately, and is NOT
included with the Installation Kit.
3. The Installation Kit includes four casters AND four 152mm
adjustable legs. The casters are provided to allow the oven
to be more easily moved to the installation location, and are
NOT suitable for use as part of the oven installation. Refer
to the notice at the beginning of this Section.
If the oven is already at the installation location, install
one 152mm adjustable leg into the center hole on the
bottom of each leg extension, as shown in Figure 2-4.
If it is necessary to move the oven to the installation
location, TEMPORARILY install the casters using the
remaining 3/8"-16x1" screws, 3/8" flat washers, and 3/
8" lockwashers. Move the oven to its final location, and
remove the casters. Then, install the 152mm adjustable
legs as described in the previous step. The threaded
studs on the adjustable legs extend through the lower
shelf and into the leg extensions. This holds the lower
shelf firmly in place.
4. Install the lower oven cavity onto the base pad. See Figure
2-4.
5. For single ovens ONLY, install the top panel using the screws
included in the base pad kit, as shown in Figure 2-5. Then,
skip ahead to Part C,
For double or triple ovens, continue on to Part B,
Note that the top panel should NOT be installed for double
and triple ovens until after stacking the oven cavities.
Figure 2-4 - Base pad installation
Conveyor Installation.
Stacking.
Bottom oven
cavity
SECTION 2 - INSTALLATION
Figure 2-3 - Leg extension and casters installation
Finished sides of
leg extension
face corner of
base pad
3/8" lock
washer
Lower
shelf
152mm adjustable
leg MUST be used
for installation
Figure 2-5 - Top panel installation
NOTE: DO NOT install top panel onto double or triple ovens
until AFTER stacking the oven cavities. See Part B,
#10 x 2" screws
attach rear of
top panel
#10 x 1" screws
attach front of
top panel
Top
panel
3/8" flat
washer
ENGLISH
3/8"-16 x 1"
hex screw
Stacking.
Assembled
base pad
9
SECTION 2 - INSTALLATION
B. Stacking
Figure 2-6 - Assembling the stacking spacers
For single ovens, skip ahead to Part C,
Installation.
IMPORTANT
Middleby Marshall STRONGLY RECOMMENDS that PS536
ENGLISH
oven cavities be stacked using the following:
PS500 Series Stacking Lift Kit, P/N 30580
PS536 Stacking Hardware Kit, P/N XXXXX
Contact your Middleby Marshall Authorized Service Agent for
complete stacking instructions.
1. Assemble the stacking spacer(s) as shown in Figure 2-6.
One spacer assembly is supplied for a double oven, while
two are supplied for a triple oven.
2. Place one of the assembled spacers on top of the lower
oven cavity, making sure that the insulation faces up.
3. Stack an oven cavity on top of the spacer. Check that all four
sides of the spacer overlap the base of the oven, and that
the oven is level and firmly seated. See Figure 2-7.
4. For triple ovens, repeat Steps 2 and 3 to install the top oven
cavity.
5. Install the top panel using the screws included in the base pad
kit, as shown in Figure 2-8.
Figure 2-7 - Stacking
Conveyor
#10-32 x 1/2"
hex screws
38mm-thick
insulation, pre-cut
Stacking panel,
P/N 44837
Top panel,
P/N 42882
Figure 2-8 - Top panel installation
Assembled
spacer
Insulation
faces up
#10 x 2" screws
attach rear of
top panel
#10 x 1" screws
attach front of
top panel
Top
panel
10
C. Conveyor Installation
SECTION 2 - INSTALLATION
PS536 ovens may be equipped with either of two different
conveyor designs. Both designs are available in single belt and
split belt configurations. Refer to Figures 2-9 and 2-10 to
determine which conveyor was shipped with your oven.
Figure 2-9 - Identifying the Type 1 conveyor
Pins on frame
fit into slots
on bracket
Some conveyors MAY be
equipped with external
bearings on drive shaft
If your oven uses the Type 1 Conveyor, continue on to Step
1 in this section, "Type 1 Conveyor Installation."
If your oven uses the Type 2 Conveyor, skip ahead to Step
2 in this section, "Type 2 Conveyor Installation."
ENGLISH
Tensioning screws
(2 per side)
Figure 2-10 - Identifying the Type 2 conveyor
Hinge plates at
center of conveyor
frame
Conveyor frame made of
rectangular steel sections
Tension adjustment
screws (2) on idler
end of conveyor
Conveyor frame made of
"C"-section stainless steel
11
SECTION 2 - INSTALLATION
1. Type 1 Conveyor Installation
a. Unfold the conveyor frame so that it lies flat on the floor.
As you unfold the frame, check that the locator pins
shown in Figure 2-11 lock into the slots on the bracket.
ENGLISH
b. Refer to Figure 2-11. Note the locations of the four
tensioning screws (2 per side) in the slotted holes on
the brackets. Loosen these screws to allow the
conveyor to be properly tensioned.
c. Lift the conveyor belt away from the frame, as shown
in Figure 2-11, to check the belt tension. The belt
should lift between 25-50mm.
Figure 2-11 - Assembling and tensioning the conveyor
Folded
frame
If it is necessary to adjust the belt tension, gently push
the two conveyor frame sections closer together, or
further apart, as required. Then, re-check the tension
of the conveyor belt. Repeat this step as necessary
until the proper belt tension is achieved.
d. When the belt tension is correctly adjusted, tighten the
two tensioning screws on each side of the conveyor
frame. This fastens the two frame sections together
at the correct belt tension.
e. If it is necessary to add or remove conveyor links to
achieve the correct tension, OR if it is necessary to
reverse the conveyor belt for correct orientation, the
belt will need to be removed from the conveyor frame.
If this is necessary, perform the following procedure:
Remove the master links using long-nose pliers.
Then, roll up the belt along the length of the
conveyor frame.
Add or remove belt links as necessary to achieve
the correct belt tension.
Replace the belt on the conveyor frame. Check
that the conveyor belt links are oriented as shown
in Figure 2-12, and that the smooth side of the
conveyor belt faces UP.
f. Connect the inside master links. Check that the links
are oriented as shown in Figure 2-12.
g. Connect the outside master links. Note that the
outside master links each have an open hook on one
side. This hook aligns with the hooks along the sides
of the other conveyor links. See Figure 2-12.
Pins on frame
fit into slots
on bracket
Tensioning
screws in slotted
holes (2 per side)
With tensioning
screws loosened,
frame sections can
be moved to adjust
belt tension
1-2" (25-50mm)
vertical deflection
Figure 2-12 - Conveyor and master link orientation
Direction
of travel
Incorrect
master link
position
12
CORRECT
master link
position
h. Lift the conveyor and position it in the oven. The
conveyor can only be installed from the end of the oven
with the drive motor.
i. Continue moving the conveyor into the oven until the
conveyor frame is positioned properly. The inside
supports for the crumb trays should rest firmly against
the lower end plugs, as shown in Figure 2-13.
j. When the conveyor is positioned properly, check for
freedom of movement of the conveyor belt by pulling it
for about 60 to 90 cm with your fingers. The conveyor
must move freely.
k. Install the drive chain between the conveyor drive
sprocket and the motor sprocket. To install the chain,
it will be necessary to lift the drive end of the conveyor
slightly.
l. Install the conveyor drive motor cover as shown in
Figure 2-15.
m. Some ovens are shipped with BOTH perforated AND
solid crumb trays, as shown in Figure 2-14. For these
ovens, the solid crumb trays should be used for the
lower (or a single) oven, while the perforated trays
should be used for all upper ovens.
Install the crumb trays as shown in Figure 2-15. First,
place the inside edge of each tray onto its support
bracket. Then, hook the outside edge of the tray over
the end of the conveyor frame.
n. Press the conveyor exit tray down over the edge of the
conveyor frame at the exit end of the oven. See Figure
2-15. Then, skip ahead to Section V,
Electrical Supply.
SECTION 2 - INSTALLATION
Figure 2-13 - Conveyor placement
Crumb tray
support
bracket
End plug
ENGLISH
Figure 2-14 - Crumb trays
Crumb trays WITH openings
(if oven is so equipped) - all
upper ovens
Crumb trays
WITHOUT openings -
lower oven only
Press conveyor
exit tray down over
end of conveyor
Figure 2-15 - Final assembly
Crumb trays
Place chain cover
down over
conveyor sprocket
2. Hook outside
edge over
conveyor frame
1. Place inside
edge on support
bracket
13
SECTION 2 - INSTALLATION
2. Type 2 Conveyor Installation
a. Partially unfold the conveyor as shown in Figure 2-16.
Then, begin to slide the conveyor into the end of the
oven. The conveyor can only be installed from the end
of the oven
ENGLISH
b. Continue moving the conveyor into the oven until the
frame protrudes equally from each end of the oven.
Check that the crumb tray supports located on the
underside of the conveyor frame rest firmly against the
lower end plugs, as shown in Figure 2-16.
c. When the conveyor is positioned properly, check for
freedom of movement of the conveyor belt by pulling it
for about 2-3 feet (0.75-1.00m) with your fingers. The
drive and idler shafts must rotate smoothly, and the
must move freely without rubbing on the inside of
belt
the oven.
d. Check the tension of the conveyor belt as shown in
Figure 2-17. The belt should lift about 25mm. DO NOT
OVERTIGHTEN THE CONVEYOR BELT.
NOTE:
If necessary, the belt tension can be adjusted by
turning the conveyor adjustment screws, located at the
idler (non-control) end of the conveyor. See Figure 2-
18.
with the drive motor.
Figure 2-16 - Conveyor installation
Folded
frame
Conveyor
placed in
oven
Figure 2-17 - Conveyor placement
Crumb tray
support
bracket
End plug
Figure 2-18 - Conveyor belt tension
25mm
vertical
deflection
Adjustment
screws (2) on
idler end of
conveyor
14
e. If it is necessary to add or remove conveyor links to
achieve the correct tension, OR if it is necessary to
reverse the conveyor belt for correct orientation, the
belt will need to be removed from the conveyor frame.
If this is necessary, perform the following procedure:
Remove the conveyor assembly from the oven
and place it flat on the floor.
Remove the master links using long-nose pliers.
Then, roll up the belt along the length of the
conveyor frame.
Add or remove belt links as necessary to achieve
the correct belt tension.
Replace the belt on the conveyor frame. Check
that the conveyor belt links are oriented as shown
in Figure 2-19, and that the smooth side of the
conveyor belt faces UP.
Connect the inside master links. Check that the
links are oriented as shown in Figure 2-19.
Connect the outside master links. Note that the
outside master links each have an open hook on
one side. This hook aligns with the hooks along
the sides of the other conveyor links. See Figure
2-19.
Replace the conveyor into the oven.
SECTION 2 - INSTALLATION
f. Install the drive chain between the conveyor drive
sprocket and the motor sprocket. To install the chain,
it will be necessary to lift the drive end of the conveyor
slightly.
Figure 2-19 - Conveyor and master link orientation
Direction
of travel
Incorrect
master link
position
CORRECT
master link
position
g. Install the conveyor chain cover as shown in Figure 2-
20. Check that the chain cover does not bind on the
conveyor sprocket or drive shaft.
h. Slide the crumb trays into place as shown in Figure 2-
20.
i. Press the conveyor exit tray down over the edge of the
conveyor frame at the exit end of the oven. See Figure
2-20. Proceed to Section V,
Electrical Supply.
ENGLISH
Press conveyor
exit tray down over
end of conveyor
Slide crumb trays
into place from
front of oven
Figure 2-20 - Final assembly
Place chain cover
down over
conveyor sprocket
15
Crumb trays rest in
support rails underneath
conveyor
SECTION 2 - INSTALLATION
IV. ELECTRICAL SUPPLY
WARNING
Authorized supplier personnel normally accomplish
the connections for the ventilation system, electric supply,
and gas supply, as arranged by the customer. Following
ENGLISH
these connections, the factory-authorized installer can
perform the initial startup of the oven.
NOTE: All aspects of the electrical supply connection must
comply with current IEC/CEE requirements and with all
applicable local, national, and international codes.
Check the oven serial plate before making any electric supply
connections. Electric supply connections must agree with data
on the oven serial plate. The location of the serial plate is shown
in Figure 1-1 (in Section 1,
A fused disconnect switch or a main circuit breaker (customer
furnished)
MUST be installed in the electric supply line for each
oven cavity. The circuit breaker/disconnect must have a minimum
of 3mm contact separation breaking all poles of the supply. It
is recommended that this circuit breaker/disconnect have
lockout/tagout capability.
The supply conductors are to be 90°C-rated copper wiring.
Additional wiring information is shown on the wiring diagrams
in Section 5,
Electrical Wiring Diagrams and inside the machin-
ery compartment of the oven.
The oven requires a ground connection to the oven ground
screw located in the electrical junction box. (The box is shown
in Figure 2-21.) The ground connection must comply with
current IEC/CEE requirements and with all applicable local,
national, and international codes. If necessary, have the
electrician supply the ground wire. Do NOT use the wiring
conduit or other piping for ground connections!
Description).
A. Additional Information - Gas Ovens
All electric supply connections are made via the electrical
junction box on the rear of the oven, shown in Figure 2-21. The
power lines then connect to the oven circuits through safety
switches located inside the machinery compartment and each
blower motor compartment. These switches interrupt electric
power to the oven when the Machinery Compartment Access
Panel is opened, OR when either of the blower or rear shrouds
is removed.
B. Additional Information - Electric Ovens
A 33mm dia. cutout in the back wall of the machinery compartment
provides access to the electrical supply connections. The
actual wiring connections are made at the terminal block
located in the electrical junction box. See Figure 2-21.
Using flexible cables for the electric power supply conductors
requires a 33mm strain-relief fitting (not furnished with the
oven) to enable safe access to the terminal block.
C. Connection
Refer to the wiring diagram inside the machinery compartment,
or in Section 5 of this Manual, to determine the correct
connections for the electrical supply lines. Connect the supply
as indicated on the wiring diagram.
If required by national or local codes, connect an equipotential
ground wire to the lug next to the
symbol (shown in Figure
2-21). The equipotential ground connection must meet all
applicable national and local code requirements.
33mm cutout for
electric utility
connection
Figure 2-21 - Utility connection locations
Electrical
Junction Box
Equipotential
ground lug
16
V. GAS SUPPLY
SECTION 2 - INSTALLATION
CAUTION
DURING PRESSURE TESTING NOTE ONE OF THE FOLLOWING:
1. The oven and its individual shutoff valve must be disconnected from the gas supply piping system during any
pressure testing of that system at test pressure in excess
of 3.45 kPa.
2. The oven must be isolated from the gas supply piping
system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at
test pressure equal to or less than 3.45 kPa.
A. Connection
WARNING
Some procedures in this section may require conversions, readjustments, or service on the oven's gas system.
Before performing these procedures, check that the main
gas supply valve and the circuit breaker/fused disconnect
are in the OFF ("O") position. After completing these procedures, perform a gas leak test before operating the oven.
CAUTION
The terms of the oven's warranty require all start-ups, conversions and service work to be performed by a Middleby Marshall
Authorized Service Agent. The installation, start-up and changes
required when changing from one gas type to another can be
performed ONLY by a certified professional.
NOTE: The gas supply connection should be according to
applicable ISO 228-1 or ISO 7-1 recommendations. All aspects
of the gas supply connection must comply with current IEC/CEE
requirements and with all applicable local, national, and international codes.
Check the ovens gas supply requirements before making the
gas utility connection. Gas supply requirements are listed on
the ovens serial plate and in Table 1-5,
Pressure Specifications (in Section 1, Description).
Check the serial plate to determine the type of gas to be used
with the oven. Check that the gas type indicated matches the
local supply at the installation. If the gas type on the serial plate
does NOT match the local supply, directions for converting the
oven for use with other gases are described in Part B,
for Use with Various Gases, in this section.
One 90° elbow equals a 2.13m length of pipe. The recommended
pipe sizes are larger than usually required to eliminate any
operation problems. It is much less expensive to make the
initial installment large enough to do the job rather than redoing
the job later.
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 2-22; however,
compliance with the applicable standards and regulations is
mandatory.
Gas Orifice and
Preparation
3. If incoming pressure is over 50mbar, a separate regulator MUST be installed in the line BEFORE the individual
shutoff valve for the oven.
WARNING: To prevent damage to the control valve regulator during initial turn- on of gas, it is
the manual shutoff valve
very slowly.
very important to open
After the initial gas turn-on, the manual shutoff valve must
remain open except during pressure testing as outlined in
the above steps or when necessary during service maintenance.
Figure 2-22 - Flexible Gas Hose Installation
3/4"-1/2"
gas pipe
reducer
Full-Flow
Shutoff
Quick-
disconnect
device
Flexible
Gas Hose
Gas
Valve
3/4" gas
pipe nipple
Elbow
90°
Individual gas
connection for
each oven
cavity
To Gas
Supply Pipe
ENGLISH
17
SECTION 2 - INSTALLATION
B. Preparation for Use with Various Gases
Before proceeding to set up the oven for a specific gas, check
that the main gas supply valve and the circuit breaker/fused
disconnect are in the OFF ("O") position.
The main orifices must match the sizes shown in Table 1-5. If
ENGLISH
necessary, replace the orifices. Refer to Part C,
Gas Orifices.
The orifice (manifold) pressure should be adjusted to the value
shown in Table 1-5 (in the
Description section) for the specific
gas type and location.
The actual heat input to the oven must match the rated heat
input. The input to the burner can be determined using the
orifice (manifold) pressure data or by the volume supplied
using the gas meter. Both of these procedures are described
in Part E,
Checking the Heat Input.
If the measured input does not correspond with the rated input
(shown in Table 1-5 in the
Description section of this Manual),
check first that the correct orifices are installed. If the orifices
are correct, check and correct the supply and orifice pressures
to obtain the correct input based on the gas meter reading.
C. Replacing the Gas Orifices (if so required)
1. Check that the main gas supply valve and the circuit
breaker/fused disconnect are in the OFF ("O") position.
2. Remove AND RETAIN the hex screws that hold the rear
wall in place. Then, remove the rear wall panel.
3. Loosen the burner tube fitting, shown in Figure 2-24.
4. Remove AND RETAIN the two screws that hold the mani-
fold in place. Remove the manifold from the oven.
5. Remove and discard the two main orifices.
6. Install the two new main orifices into the manifold.
7. Replace the manifold into the oven. Fasten it in place with
the two original mounting screws, and tighten the burner
tube fitting.
WARNING
After completing these procedures, perform a gas
leak test before operating the oven.
Replacing the
Flame
sensor
Ignitor
Manifold
pressure tap
(under cap
screw)
Inlet
pressure tap
(under cap
screw)
Figure 2-23
In-shot
burners (2)
Modulating
gas valve
Ignition
module
Gas
control
valve
Pressure
adjustment screw
(governor - under
cap screw)
18
Burner
tube fitting
Figure 2-24
Main orifices
(2)
Screws (2)
D. Checking the Gas Supply (Inlet) Pressure
1. Remove the supply (inlet) pressure cap screw from the gas
control valve. Attach a manometer to the stud.
2. Depress the safety switches to allow the oven to operate.
3. Open the main gas supply valve. Switch the circuit breaker/
fused disconnect to the ON ("I") position.
4. Start the oven according the directions in the
Operation
section of this Manual. Adjust the temperature controller to
the maximum setting (316°C).
5. Measure the supply (inlet) pressure.
6. Switch the oven off. Close the main gas supply valve, and
switch the circuit breaker/fused disconnect to the OFF ("O")
position. Remove the manometer, and replace the cap
screw onto the gas control valve.
7. Compare the measured supply (inlet) pressure to the
nominal pressures shown in Table 1-5 (in the Description
section of this Manual).
If the supply pressure is lower or higher than the nominal
pressure, the reason should be investigated and the gas
supplier contacted.
For natural gas ovens, if the measured supply pressure is lower
than 17mbar, or higher than 25mbar, contact the gas supplier.
DO NOT OPERATE THE OVEN or adjust the oven controls.
E. Adjusting the Orifice (Manifold) Pressure and Heat Input
To use the orifice pressure method, you must know the specific
gas type and quality used. If using the orifice pressure method,
you should double-check the input using the volumetric method.
To use the volumetric method, you must know the heat value
(HuB) of the gas used. This information is available from your
gas supplier.
During these measurements, do not operate any other
appliances that use the same gas meter as the oven.
1. Orifice (Manifold) Pressure Method
a. Check that the main gas supply valve and the circuit
breaker/fused disconnect are in the OFF ("O") position.
b. Remove the regulated (manifold) pressure cap screw
from the gas control valve. Attach a manometer to the
stud.
c. Remove the cap screw from the pressure adjustment
screw (governor) on the gas control valve.
d. Depress the safety switches to allow the oven to
operate.
e. Open the main gas supply valve. Switch the circuit
breaker/fused disconnect to the ON ("I") position.
f. Start the oven according the directions in the
Operation
section of this Manual. Adjust the temperature controller
to the maximum setting (316°C).
g. Adjust the pressure adjustment screw as necessary
to match the correct pressure for the oven's specific
gas type. Refer to Table 1-5 in the
Description section
of this Manual. Turning the adjustment screw clockwise
increases the flow, while turning it counterclockwise
reduces the flow.
h. Switch the oven off. Close the main gas supply valve,
and switch the circuit breaker/fused disconnect to the
OFF ("O") position. Remove the manometer, and
replace the cap screws onto the gas control valve.
SECTION 2 - INSTALLATION
2. Volumetric Method
3
a. Determine the time of 0.1m
(100 liters) of gas usage
as follows.
Consumption (m
3
/hr.) =
NB (Rated input in kW)
HuB (Heat [Calorific] value
of gas in kW/m3)
Time (in minutes) of
0.1m3 of gas usage
=
6
Consumption
b. Check that the main gas supply valve and the circuit
breaker/fused disconnect are in the OFF ("O") position.
c. Remove the cap screw from the pressure adjustment
screw (governor) on the gas control valve.
d. Depress the safety switches to allow the oven to
operate.
e. Open the main gas supply valve. Switch the circuit
breaker/fused disconnect to the ON ("I") position.
f. Start the oven according the directions in the
section of this Manual. Adjust the temperature controller
to the maximum setting (316°C).
g. Adjust the pressure adjustment screw as necessary
to match the calculated volume using the time (in
minutes) of 0.1m
3
of gas usage. Turning the
adjustment screw clockwise increases the flow, while
turning it counterclockwise reduces the flow.
h. Record the reading obtained from the gas meter and
calculate the obtained gas flow. Compare this value
to the information in Table 1-4 in the
Description
section of this Manual.
i. Switch the oven off. Close the main gas supply valve,
and switch the circuit breaker/fused disconnect to the
OFF ("O") position. Replace the cap screw onto the
gas control valve.
ENGLISH
Operation
19
SECTION 2 - INSTALLATION
ENGLISH
NOTES:
20
SECTION 3 - OPERATION
I. LOCATION AND DESCRIPTION OF CONTROLS
Fig. 3-1 - Control Panel
E
ENGLISH
E
A
B
C
D
A.
B.
C.
D.
"BLOWER" Switch: Turns the blowers and
cooling fans on and off. When set to the "ON" (I)
position, it also allows the heating elements to
activate. Activation is determined by the settings on the Digital Temperature Controller.
"CONVEYOR" Switch: Turns the conveyor drive
motor on and off.
Conveyor Speed Controller: Adjusts and displays the bake time. Single-belt ovens have one
controller. Split belt ovens have one controller
for each conveyor belt, labeled "FRONT" and
"BACK."
"RESET" Switch: Gas ovens only. Illuminates
if the gas burner does not light. The switch can
be pressed repeatedly to attempt to light the
burner. If the burner does not light within 15
minutes, the "RESET" (
) switch is locked out.
E.
NOT SHOWN:
F. Machinery Compartment Access Panel Safety Switch:
Disconnects electrical power to the controls and the blowers when the machinery compartment access panel is
opened. The panel should only be opened by authorized
service personnel.
Digital Temperature Controller: Continuously
monitors the oven temperature. Settings on the
Digital Temperture Controller control the activation of the burner or heating elements. Keypad
controls allow the operator to select the cooking
temperature and monitor oven operation.
Note that two different models of Digital Temperature Controller are used on PS536 ovens.
This section provides instructions specific to
each controller.
21
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
ENGLISH
position. Check that the window (if so equipped) 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.
o r
or
If the oven uses this
Digital Temperature
Controller:
5a. Press the
pushbuttons on the digital temperature controller to adjust the set temperature, if necessary.
Note that the set temperature is shown in the lower
window of the display,
while the actual oven
temperature is shown in
the upper window.
6a. Check that the "1" light
illuminates. This shows
that the burner or heating
elements have been
turned on.
The "2" light will illuminate while the oven heats
to its minimum normal
operating temperature of
93°C.
or
Actual
temp
Set
temp
or
Heating
elements on
Oven
temperature
under 200°F/
93°C
7a. Wait for the oven to heat to the set point temperature. Higher
set point temperatures will require a longer wait. The oven
can reach a temperature of 232°C in approximately 15
minutes.
8a. Allow the oven to preheat for 10 minutes after it has reached
the set point temperature.
22
B. DAILY SHUTDOWN PROCEDURE
SECTION 3 - OPERATION
If the oven uses this
Digital Temperature
Controller:
5b. 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.
Press the Up Arrow
and Down Arrow
Keys as necessary
to adjust the setpoint.
or
+
wait
for
1. Turn the "BLOWER" ( )
and "CONVEYOR" (
switches to the "OFF"
("O") position. Open the
window (if so equipped)
to allow the oven to cool
faster.
Note that the blowers will
remain in operation until
the oven has cooled to
below 93°C.
2. After the oven has cooled and the blowers are off, switch the
circuit breaker/fused disconnect to the off 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.
On gas ovens, 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.
ENGLISH
6b. Check that the "HEAT ON"
light illuminates. This
shows that the burner or
heating elements have
been turned on.
7b. (Gas ovens only) If the "RE-
SET" (
nates, the gas burner did
not light. Press the "RESET" (
edly if necessary) to attempt to light the burner.
NOTE: If the burner does not light within 15 minutes, the
oven enters a safety lockout mode that disables the "RESET" (
"BLOWER" (
"OFF" ("O") position.
Then, repeat the Daily Startup procedure.
8b. 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 232°C in approximately 5
minutes.
) switch illumi-
) switch (repeat-
) switch. If this occurs, turn the "HEAT" ( ),
), and "CONVEYOR" ( ) switches to the
Wait for AT LEAST FIVE MINUTES.
wait
for
9b. Allow the oven to preheat for 10 minutes after it has reached
the set point temperature.
23
SECTION 3 - OPERATION
III. QUICK REFERENCE: DIGITAL TEMPERATURE CONTROLLERS
ENGLISH
Upper display
Shows the actual
oven temperature.
Lower display
Shows the set
point temperature.
Illuminates when the burner
light
or heating elements are on.
This light will flicker during
normal operation after the
oven reaches the set point
temperature.
light
Illuminates when
oven temperature is
EITHER below 93°C
OR above 316°C.
Percent
indicator
light
Service use only.
Advance key
Service use only.
Up Arrow key
Increases the set
point temperature.
Press the key once
to change the set
point by one degree.
Hold the key down
for larger changes.
Infinity key
Service use only.
Down Arrow key
Decreases the set point
temperature. Press the
key once to change the
set point by one degree.
Hold the key down for
larger changes.
24
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 343°C.
Refer to
Reference: Trouble-
shooting in this
Quick
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 or heating
elements, as
appropriate for the
oven model, are in
operation.
ENGLISH
"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
Point Key and Unlock Key
in this section.
25
Set
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.
SECTION 3 - OPERATION
IV. QUICK REFERENCE: TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
The oven temperature is in
excess of 316°C. If the oven
is left in operation, the temperature may rise to 343°C
and cause a shutdown.
The oven temperature exceeded 343°C, and the oven
was automatically shut
down.
ENGLISH
light illuminates
oven has been
operating normally
Oven shuts down
completely during operation
light is lit, oven will
not heat
after
Turn the oven off according to the
Allow the oven to cool. Regardless of the time that is required
for the oven to cool, wait for AT LEAST FIVE MINUTES before
restarting the oven.
Repeat the
Turn the oven off according to the Daily Shutdown Procedure.
Contact your Middleby Marshall Authorized Service Agent to
determine and correct the cause of the condition to prevent
damage to the oven.
Daily Startup Procedure.
Daily Shutdown Procedure.
The oven did not reach
appears in display, oven is not
heating
"RESET" (
illuminated, oven will not
(gas ovens only)
Oven will not
turn on at all
Oven will not heat Controls may be set incor-
Oven is operating, but
little or no air is blowing
from air fingers
) switch is
heat
93°C within 15 minutes of
startup, and has stopped
heating.
The gas burner did not light
within 90 seconds of turning the "HEAT" (
to the ON ("I") position.
Electrical power may not be
reaching the oven, or the
controls may be set incorrectly.
rectly.
Air fingers may have been
reassembled incorrectly
after cleaning.
Blower belt may be broken.
) Switch
Turn the "BLOWER"
the "OFF" ("O") position.
Wait for AT LEAST FIVE MINUTES before restarting the oven.
Repeat the Daily Startup procedure.
Press the "RESET" (
attempt to light the burner.
If the burner does not light within 15 minutes, the oven will enter
a safety lockout mode that disables the "RESET" (
If this occurs, turn the "HEAT" (
"CONVEYOR" (
for AT LEAST FIVE MINUTES before restarting the oven. Then,
repeat the Daily Startup procedure.
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.
Check that the Set Point is correctly set.
Check that the "BLOWER"
position.
If the oven still will not heat, turn the oven off according to the
instructions in the
Wait for AT LEAST FIVE MINUTES before restarting the oven.
Repeat the
is above 93°C.
Turn the oven off according to the
Refer to Section 4,
bling the air fingers.
Turn the oven off according to the
Contact your Middleby Marshall Authorized Service Agent to
correct the problem.
Daily Startup Procedure. Check that the Set Point
( ) and "CONVEYOR" ( )switches to
) switch (repeatedly if necessary) to
) switch.
), "BLOWER" ( ), and
)switches to the "OFF" ("O") position. Wait
( ) Switch is in the ON ("I")
( ) Switch is in the ON ("I")
Daily Shutdown Procedure.
Daily Shutdown Procedure.
Maintenance, for instructions on reassem-
Daily Shutdown Procedure.
Conveyor moves with a
jerky motion, or will not
move at all
Food products are
overcooked or
undercooked
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.
Conveyor may be jammed
on an object in the oven, or
conveyor belt or drive chain
may be overtightened.
Controls may be set incorrectly.
Turn the oven off according to the
Check if the conveyor is blocked by an object inside the oven.
Check that the conveyor drive chain is not overtightened.
Refer to Section 4,
the conveyor belt tension.
Check that the set temperature and bake time settings are
correct.
26
Maintenance, for instructions on checking
Daily Shutdown Procedure.
SECTION 4 - MAINTENANCE
WARNING
Before ANY cleaning or servicing of the oven, perform the following procedure:
1. Switch off the oven and allow it to cool. Do NOT service the oven while it is warm.
2. Turn off the electric supply circuit breaker(s)
3. If it is necessary to move a gas oven for cleaning or servicing, disconnect the gas supply connection before moving the oven.
and disconnect the electric supply to the oven.
When all cleaning and servicing is complete:
1. If the oven was moved for servicing, return the oven to its
original location.
2. For gas ovens, reconnect the gas supply.
3. Reconnect the electrical supply.
4. For gas ovens, turn on the full-flow gas safety valve. Test
the gas line connections for leaks using approved leak
test substances or thick soap suds.
5. Turn on the electric supply circuit breaker(s).
6. Perform the normal startup procedure.
WARNING
Possibility of injury from moving parts and electrical shock exists in this oven. Switch off and lockout/tagout the electric supply
BEFORE beginning to disassemble, clean, or service any oven. Never disassemble or clean an oven with the BLOWER
switch or any other circuit of the oven switched on.
CAUTION
NEVER use a water hose, water jet, or pressurized steam-cleaning equipment when cleaning this oven. DO NOT use
excessive amounts of water, to avoid saturating the oven insulation. DO NOT use a caustic oven cleaner, which can damage
the aluminized bake chamber surfaces.
NOTE
ANY replacement parts that require access to the interior of the oven may ONLY be replaced by a Middleby Marshall Authorized
Service Agent. It is also strongly recommended that the 3-Month Maintenance and 6-Month Maintenance procedures in this
section be performed ONLY by a Middleby Marshall Authorized Service Agent.
I. MAINTENANCE - DAILY
A. Check that the oven is cool and the power is disconnected,
as described in the warning at the beginning of this Section.
B. Clean ALL of the cooling fan grills and vent openings with a
stiff nylon brush. Refer to Figure 4-1 for the locations of the
grills and vents.
C. Clean the outside of the oven with a soft cloth and mild
detergent.
D. Check that ALL cooling fans are operating properly.
CAUTION
If a cooling fan is not operating correctly, it must be replaced
IMMEDIATELY. Operating the oven without adequate
cooling can seriously damage the oven's internal components.
E. Clean the conveyor belts with a stiff nylon brush. This is
more easily accomplished by allowing the conveyor to run
while you stand at the exit end of the conveyor. Then, brush
the crumbs off the conveyor as it moves.
F. Remove and clean the crumb trays. Be sure to replace the
trays in the same positions from which they were removed,
because they are NOT identical. Refer to Figure 2-11 (in
Section 2,
G. Clean the window (if so equipped) in place.
Installation).
Vents on
front panel
of oven
Vents on rear of
machinery
compartment
access panel
Figure 4-1 -Cooling Vents and Grills
Grills/vents
on rear of
oven
ENGLISH
( )
27
SECTION 4 - MAINTENANCE
II. MAINTENANCE - MONTHLY
A. Check that the oven is cool and the power is disconnected,
as described in the warning at the beginning of this Section.
B. Refer to Part C,
ENGLISH
section of this Manual. Then, remove the following components from the oven:
Conveyor exit tray
Crumb trays
Chain cover
End plugs
Conveyor assembly
C. Slide the air fingers and blank plates out of the oven, as
shown in Figure 4-2. AS EACH FINGER OR PLATE IS
REMOVED, WRITE A "LOCATION CODE" ON IT WITH A
MARKER to make sure that it can be reinstalled correctly.
Example of markings:
(Top Row) T1 T2 T3 T4
(Bottom Row) B1 B2 B3 B4
D. Disassemble the air fingers. See Figure 4-3. AS EACH
FINGER IS DISASSEMBLED, WRITE THE "LOCATION
CODE" FOR THE FINGER ON ALL THREE OF ITS PIECES.
This will help you in correctly reassembling the air fingers.
CAUTION
Incorrect reassembly of the air fingers will change the
baking properties of the oven.
E. Clean the air finger components and the interior of the
baking chamber using a vacuum cleaner and a damp cloth.
Refer to the boxed warnings at the beginning of this Section
for cleaning precautions.
F. Reassemble the air fingers. Then, replace them in the
oven, using the "location code" as a guide.
G. Install the end plugs on the oven. Then, reinstall the
conveyor.
H. Reattach the drive chain. Replace the chain cover.
I. Check the tension of the conveyor belt as shown in Figure
2-7 (in Section 2,
25-50mm. If necessary, adjust the belt tension using the
procedure in Part C (
tion section of this Manual.
J. Replace the crumb trays and exit tray onto the oven.
Conveyor Installation, in the Installation
Installation). The belt should lift between
Conveyor Installation) in the Installa-
Figure 4-2 - Removing Air Fingers and Plates
Figure 4-3 - Disassembling the Air Fingers
Outer Plate
Inner plate
Manifold
III. MAINTENANCE - EVERY 3 MONTHS
A. Check that the oven is cool and the power is disconnected,
as described in the warning at the beginning of this Section.
B. Open the machinery compartment access panel. Vacuum
the inside of the compartment using a shop vacuum.
C. Tighten all electrical control terminal screws.
28
D. Split Belt Disassembly and Cleaning
For split belt ovens ONLY, disassemble, clean and lubricate the
conveyor shaft components as described in this Section.
PS536 ovens may be equipped with either of two different
conveyor designs. Both designs are available in split belt
configurations. Refer to Figures 4-4 and 4-5 to determine which
conveyor was shipped with your oven.
SECTION 4 - MAINTENANCE
If your oven uses the Type 1 Conveyor, continue on to Step
1 in this section, "Type 1 Conveyor Split Belt Cleaning."
If your oven uses the Type 2 Conveyor, skip ahead to Step
2 in this section, "Type 2 Conveyor Split Belt Cleaning."
Figure 4-4 - Identifying the Type 1 split belt conveyor
Pins on frame
fit into slots
on bracket
Tensioning screws
(2 per side)
Conveyor frame made of
rectangular steel sections
ENGLISH
Figure 4-5 - Identifying the Type 2 split belt conveyor
Hinge plates at
center of conveyor
frame
Conveyor frame made of
"C"-section stainless steel
29
Tension adjustment
screws (2) on idler
end of conveyor
SECTION 4 - MAINTENANCE
1. Type 1 Conveyor Split Belt Cleaning
Figure 4-6 - Disassembling the drive shaft
a. Refer to Part C,
Conveyor Installation, in the Installation
section of this Manual. Then, remove the following components from the oven:
ENGLISH
Conveyor exit tray
Crumb trays
Chain cover
End plugs
Conveyor assembly
b. Remove the master links from each conveyor belt. Then,
roll the belts up along the length of the conveyor to remove
them from the frame.
c. Loosen (DO NOT REMOVE) the set screw on the outer drive
sprocket. Then, slide the drive sprocket off the end of the
drive shaft. See Figure 4-6.
d. Loosen (DO NOT REMOVE) the set screws on all four steel
spacers (2 per shaft), AND on all twelve conveyor belt
sprockets (6 per shaft).
e. Gently work the shaft sections out of the conveyor frame,
removing the conveyor belt sprockets as necessary. See
Figures 4-6 and 4-7.
f. Slide the two sections of each shaft apart.
g. Clean all of the shaft components thoroughly using a rag.
Then, lubricate each solid inner shaft, AND the interiors of
each hollow shaft, using a light food-grade lubricant.
NOT lubricate the shafts using WD40 or a similar product.
This can cause the shafts to wear rapidly.
h. Slide the hollow shaft sections over the solid inner shafts.
Check that the hollow section that has a drive sprocket
attached is placed at the end of the the drive shaft.
i. Slide the reassembled shafts into the conveyor frame. As
the shafts are replaced, slide the steel spacers and conveyor belt sprockets onto the shafts. Refer to Figures 4-6
and 4-7.
j. After the shafts are properly aligned, position the steel
spacers against the ends of the bushings on the conveyor
frame. Tighten the set screws on the spacers to hold them
in place. Leave the conveyor belt sprockets loose at this
time.
k. Replace the outer drive sprocket. Tighten its set screw to
hold it in place.
l. Refer to Part C,
Conveyor Installation, in the Installation
section of this Manual to replace the conveyor belt. As you
replace the belt, position the conveyor belt sprockets.
m. After the belt is in place and the sprockets are correctly
positioned, tighten the set screws to hold the sprockets in
place.
n. Reinstall the end plugs and conveyor onto the oven.
o. Reattach the drive chains. Replace the chain cover.
p. Check the tension of the conveyor belt as shown in Figure
2-11 (in Section 2,
Installation). The belt should lift between
25-50mm. If necessary, adjust the belt tension using the
procedure in Part C (
Conveyor Installation) in the Installa-
tion section of this Manual.
q. Replace the crumb trays and exit tray onto the oven. Then,
skip ahead to Part E, "Blower Belt."
DO
Spacer (2)
Smooth
sprocket (2)
Spacer (2)
Smooth
sprockets (6)
2. Loosen set
screws on belt
sprockets and
spacers (8)
Sprockets
w/teeth (4)
1. Remove outer
drive sprocket
Bushing
4. Disassemble,
clean, and
lubricate shafts
3. Slide shafts out
of frame
Figure 4-7 - Disassembling the idler shaft
1. Loosen set
screws on belt
sprockets and
spacers (8)
Bushing
2. Slide shafts out
of frame
30
3. Disassemble,
clean, and
lubricate shafts
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