Middleby Marshall PS540 Installation Manual Page 1

©2003 Middleby Marshall Inc.MiddlebyMiddlebyMiddlebyMiddlebyMiddlebyMarshallMarshallMarshallMarshallMarshallA MIDDLEBY COMPANYPS540-Series Gas Ovens:

6SECTION 1DESCRIPTIONIII. COMPONENT FUNCTIONA. Conveyor Motor and Conveyor BeltThe conveyor belt is driven by a variable-speed electricmotor (Figure 1

SECTION 1DESCRIPTION7Figure 1-8. Cooling FanCooling Fan GrilleE. Cooling Fan — See Figure 1-8The cooling fans are located in the back of the oven.The

8SECTION 1DESCRIPTIONHalf Blank PlateBlank PlateOuter PlateInner PlateFinger Manifold AssemblyBaffleFigure 1-9. Blank Plates (two sizes) and an Air F

SECTION 2INSTALLATION9SECTION 2INSTALLATIONNOTE: In U.S.A., the oven installation must conform withlocal codes, or in the absence of local codes, wit

10SECTION 2INSTALLATIONPS540 OVEN INSTALLATIONREQUIRED KITS AND EQUIPMENTTYPE PS540 PS540 Single PS540 Double PS540 Double PS540 TripleOF Gas Oven O

SECTION 2INSTALLATION11PARTS LIST FOR PS540 SERIES SINGLE OVEN OPTION - BASE w/15″″″″″ LEGS & TOPP/N 34832ITEMNO. QTY PART NO. DESCRIPTION1 1 3790

12SECTION 2INSTALLATIONPARTS LIST FOR PS540 SERIES DOUBLE OVEN OPTION - BASE w/6″″″″″ LEGS, CASTERS & TOPP/N 34833ITEMNO. QTY PART NO. DESCRIPTION

SECTION 2INSTALLATION13PARTS LIST FOR PS540 SERIES TRIPLE OVEN OPTION - BASE w/CASTERS & TOPP/N 51139ITEMNO. QTY PART NO. DESCRIPTION1 1 54606 COM

14SECTION 2INSTALLATIONFigure 2-5. MODEL PS540 SINGLE OVEN DIMENSIONSGAS INLETELECTRICAL JUNCTION BOXRECOMMENDED MINIMUM CLEARANCES:Rear of Oven to W

SECTION 2INSTALLATION15Figure 2-6. MODEL PS540 DOUBLE OVEN DIMENSIONSGAS INLETELECTRICAL JUNCTION BOXRECOMMENDED MINIMUM CLEARANCES:Rear of Oven to W

iiWARNINGFOR YOUR SAFETY, DO NOT STORE OR USEGASOLINE OR OTHER FLAMMABLE VAPORS ANDLIQUIDS IN THE VICINITY OF THIS OR ANY OTHERAPPLIANCE.WARNINGPOST,

16SECTION 2INSTALLATIONRESTRAINT CABLE INSTALLATIONInstall the restraint cable assembly on the oven, as shownin Figure 2-6.Figure 2-7. MODEL TRIPLE O

SECTION 2INSTALLATION17WARNINGDO NOT USE CONDUIT OR GAS LINEFOR GROUND CONNECTION.CAUTIONIT IS REQUIRED THAT THE OVEN BEPLACED UNDER A VENTILATIONHOOD

18SECTION 2INSTALLATION II. VENTILATION GUIDELINESA mechanically driven ventilation system is required forthe PS540 Series Middleby Marshall conveyori

SECTION 2INSTALLATION19III. ELECTRICAL CONNECTIONINFORMATION FOR PS540-SERIESOVENS.WARNINGAuthorized supplier personnel normally accom-plish the conne

20SECTION 2INSTALLATIONV. GAS SUPPLY FOR GAS HEATEDOVENSWARNINGDuring gas line pressure testing, observe thefollowing precautions:1. The oven and its

SECTION 2INSTALLATION21A. ConnectionCheck the oven’s gas supply requirements before making thegas utility connection. Gas supply requirement are lis

22SECTION 2INSTALLATIONE. Adjusting the Minimum Pressure Setting1. Disconnect pressure feedback connection (if appcable).2. Connect a suitable pressur

SECTION 3OPERATION23SECTION 3OPERATIONI. CONTROL FUNCTIONSWARNINGThe burner cannot operate and gas cannot flowthrough the burner without electric powe

24SECTION 3OPERATIONII. COMPONENT INFORMATION ANDLOCATION (Figures 3-1 and 3-2)A. Door Safety SwitchThe Door Safety Switch is located at the lower le

SECTION 3OPERATION25E. ConveyorThe on-off switch for the conveyor motor is on the controlpanel. Also on the control panel is the digital conveyorspee

iiiMIDDLEBY MARSHALL INC.OVEN LIMITED WARRANTY(Non U.S.A.)The Seller warrants equipment manufactured by it to be free fromdefects in material and work

26SECTION 3OPERATIONWARNING OVEN MUST BE KEPT CLEAR OFCOMBUSTIBLES AT ALL TIMES.III. STEP-BY-STEP OPERATIONControl Panel (On split belt ovens, two con

SECTION 3OPERATION27Figure 3-6. Control Panel

28SECTION 3OPERATIONCAUTIONIn case of power failure, turn all switches to the “OFF”("O") position, open the oven window, and removethe produ

SECTION 3OPERATION29DisplayShows the Set Pointor the Actual Tem-perature in degreesFahrenheit (F) orCelsius (C)."SP LOCK"LightLights when t

30SECTION 3OPERATIONIV. QUICK REFERENCE: TROUBLESHOOTINGSYMPTOM PROBLEM SOLUTIONThe oven temperature ex-ceeded 650°F (343°C), andthe burner was autom

SECTION 4MAINTENANCE31SECTION 4MAINTENANCEWARNINGPossibility of injury from rotating parts and electricalshock exist in this oven. Turn off and lockou

32SECTION 4MAINTENANCEI. MAINTENANCE - DAILYA. ExteriorEveryday you should clean the outside of the oven with asoft cloth and mild detergent.WARNINGNe

SECTION 4MAINTENANCE33Figure 4-3.II. MAINTENANCE - MONTHLYWhen cleaning your Series PS540 Oven note thefollowing:PRECAUTIONS-1. Do not use excessive

34SECTION 4MAINTENANCE4. Remove conveyor drive chain cover as shown.5. Remove tension from drive chain by lifting and pushingthe conveyor slightly int

SECTION 4MAINTENANCE35B. Air Fingers Disassembly For Cleaning1. As the air fingers are removed use a felt pen to mark allparts of the fingers. This in

ivNOTEWiring Diagrams are in Section 7 of this Manual.The diagram for each oven is also on the lowerinner surface of its Control Console.TABLE OF CONT

36SECTION 4MAINTENANCE6. 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 clean

SECTION 4MAINTENANCE372. Reassemble the inner plate. Keep your fingers clear soyou won’t pinch them. The inner plate of a finger will onlygo in one wa

38SECTION 4MAINTENANCE5. Install fingers and blank plates correctly with edgesinterlocked and no space between edges.Figure 4-21.Top FingerIncorrect -

SECTION 4MAINTENANCE39E. Reinstall End Plugs1. Reinstall lower end plug. Be sure to tighten two wingscrews on the end plug.2. Reinstall conveyor.3. Re

40SECTION 4MAINTENANCEG. Checking Conveyor Belt TensionWARNINGOven conveyor belt must be cool when adjustingbelt. Do not adjust belt if HOT.1. With th

SECTION 4MAINTENANCE41H. Conveyor Belt Link Removal1. Using long nose pliers, an entire link can be removedwith the conveyor assembly either in or out

42SECTION 4MAINTENANCEI. Replacing Conveyor BeltIf a section of the conveyor belt needs replacing it can bedone with the conveyor assembly either in o

SECTION 4MAINTENANCE434. Reassemble conveyor drive chain cover and thenreassemble the bottom cover to the drive chain cover.Install both upper end plu

44SECTION 4MAINTENANCEB. Electrical TerminalsOpen the control cabinet door by removing the threescrews from the control cabinet door. Tighten all elec

SECTION 4MAINTENANCE45E. Blower Fan Shaft Bearing LubricationCAUTIONOver-greasing damages the bearing seals andaccelerates grease loss, which shortens

SECTION 1DESCRIPTION1I. MODEL IDENTIFICATIONThe Middleby Marshall PS540-Series may be used eitheras a single oven or stacked for use as double or trip

46SECTION 4MAINTENANCE6. Make sure bronze washer is in between the two halves.Figure 4-47.7. Place the idler shaft assembly back into place andreinsta

SECTION 4MAINTENANCE4712. Slide shaft assembly to right side, holding assemblyin place. Slide split locking collar to the left side andtighten.13. Sli

48SECTION 4MAINTENANCEPS540-SERIES GAS OVEN KEY SPARE PARTS (Figure 4-56)ITEM PART NO. ENGLISH DESCRIPTION QUANTITY1 47321 Temperature Controller 12 4

49SECTION 5TROUBLESHOOTINGSECTION 5TROUBLESHOOTINGPROBLEM:PRODUCTS ARE OVERCOOKEDOR UNDERCOOKEDCheck for correctsetting of conveyorspeed control.Set t

SECTION 5TROUBLESHOOTING50NOTES

51ENGLISHSECTION 6PARTS LISTSECTION 6 - PARTS LIST

52ENGLISHSECTION 6PARTS LIST

53ENGLISHSECTION 6PARTS LISTOVEN PANELS, WINDOW AND LEGSITEM QTY. P/N DESCRIPTION1 2 49947 UPPER END PLUG ASSEMBLY2 2 49946 LOWER END PLUG ASSEMBLY3 8

54ENGLISHSECTION 6PARTS LIST

55ENGLISHSECTION 6PARTS LISTCONTROL PANELITEM QTY. P/N DESCRIPTION1 1 47321 COMBO BURST CONTROL, 4-20Ma2 1 33812-3 THERMOCOUPLE, TYPE J SHIELDED 9.50

2SECTION 1DESCRIPTIONPS540 SERIES OVEN SPECIFICATIONSConveyor Belt Width 32″ (813mm)Heating Zone Length 40-1/2″ (1028mm)Baking Area Square Feet 9 sq.

56ENGLISHSECTION 6PARTS LIST

57ENGLISHSECTION 6PARTS LISTBLOWER AND SHROUDITEM QTY. P/N DESCRIPTION1 1 51157 PULLEY, 1GRV 3.0PD AK32H2 1 48855 WELDMENT, BRG BRACKET PS540G3 22 220

58ENGLISHSECTION 6PARTS LIST

59ENGLISHSECTION 6PARTS LISTCONVEYORITEM QTY. P/N DESCRIPTION1 1 47042 SINGLE CONVEYOR 80″EXCLUDES ITEMS 7, 8, 9, 12, 36 & 372 1 22450-0225 CONVEY

60ENGLISHSECTION 6PARTS LIST

61ENGLISHSECTION 6PARTS LISTSPLIT BELT CONVEYORITEM QTY. P/N DESCRIPTIONITEM QTY. P/N DESCRIPTION1 1 50646 SPLIT CONVEYOR 50/50 80″EXCLUDES ITEMS 7,

62ENGLISHSECTION 6PARTS LIST1234561314710121198

63ENGLISHSECTION 6PARTS LISTGAS BURNER AND PIPING ASSEMBLYITEM QTY. P/N DESCRIPTION1 1 50275 ASSY, BURNER/BLOWER2 1 36937 GASKET, DS-22 BURNER FLANGE3

64ENGLISHSECTION 6PARTS LIST

65ENGLISHSECTION 6PARTS LISTMACHINERY COMPARTMENTITEM QTY. P/N DESCRIPTION1 1 28021-0047 INTERLOCK SWITCH 10A NO2P2 1 28021-0061 MOMENTARY SWITCH - 10

SECTION 1DESCRIPTION3II. PRINCIPLE OF AIR FLOWThe fan-style blower draws air into the oven plenum whereit is heated. The blower then pushes the hot a

66ENGLISHSECTION 6PARTS LISTNOTES

67SECTION 7ELECTRICAL SCHEMATICSSECTION 7ELECTRICAL SCHEMATICSWiring Diagram, G208-240 50/60, 1PH 3W PS54050141H

SECTION 7ELECTRICAL SCHEMATICS68Wiring Diagram, G208-240 50/60, 1PH 3W PS54050141H

69SECTION 7ELECTRICAL SCHEMATICSNOTES

SECTION 7ELECTRICAL SCHEMATICS70NOTES

NOTES

Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • USA • (847)741-3300 • FAX (847)741-440624-Hour Service Hotline: 1-(800)-2

4SECTION 1DESCRIPTIONSeries ovens used to bake pizza have four bottom fingersand two top fingers. For special product baking require-ments, a number o

SECTION 1DESCRIPTION5III. COMPONENT FUNCTION (Figure 1-6)Figure 1-6. PS540-Series Oven Components Locations