Middleby Cooking Systems Group Oven PS870 Series User Manual

PS870 Series

Gas

Domestic

ENGLISH

P/N59157

August 4, 2006

PS870 Series Gas Ovens

Model:

• PS870G Gas

Combinations:

• SingleOven

• DoubleOven(Two-Stack)

• TripleOven(Three-Stack)

OWNER'S OPERATING AND

INSTALLATION MANUAL

for domestic and standard export ovens

Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • (847)741-3300 • FAX (847)741-4406

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Model No.

Modéle No.

Serial No.

Serié No.

Installation Date

Date d'installation

MIDDLEBY MARSHALL

N^OQUIBBLE LIMITED WARRANTY

(U.S.A. ONLY)

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

installationor15monthsfromdateofshipmentfromSeller’sfactory,

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.

MIDDLEBY MARSHALL, HEREINAFTER REFERREDTO 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 UNDERTHISWARRANTY SHALL

BE LIMITEDTO 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 EFFEC-

TIVE FOR A PERIOD OF ONEYEAR FROM DATE OF ORIGI-

NAL INSTALLATION, OR 18 MONTHS FROM DATE OF PUR-

CHASE,WHICHEVER IS EARLIER, PROVIDEDTHATTERMS

OF PAYMENT HAVE BEEN FULLY MET.

This warranty is not valid unless equipment is installed,

started, and demonstrated under the supervision of a fac-

tory-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.

This warranty is valid only if the equipment is installed, started,

and demonstrated under the supervision of a factory-autho-

rized installer.

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.

Normal maintenance functions, including lubrication, cleaning,

or customer abuse, are not covered by this no quibble war-

ranty.

When returning any part under warranty, the part must be intact and

complete, without evidence of misuse or abuse, freight prepaid.

Seller shall be responsible only for repairs or replacements of

defective parts performed by Seller’s authorized service per-

sonnel. 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.

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 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 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 shall be Seller’s sole and exclusive obligation

and Buyer’s sole and exclusive remedy for any action, includ-

ing 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.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF

ALL OTHER EXPRESS AND IMPLIED WARRANTIES WHATSO-

EVER. SPECIFICALLY THERE ARE NO IMPLIED WARRANTIES

OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR

PURPOSE.

This warranty is effective on Middleby Marshall equip-

ment sold on, or after, February 15, 1995.

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 logo is a registered trademark of Middleby Marshall, A Middleby Company.

Middleby Marshall Inc. • 1400Toastmaster Drive • Elgin, Illinois 60120-9272 U.S.A.• (847) 741-3300 • FAX:(847) 741 4406

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Table of Contents

Page

SECTION 1

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

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

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

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

D. Standoff Installation ................................................ 10

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

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

Connection .................................................................. 12

VII. GAS SUPPLY ............................................................. 12

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

B. Connection ............................................................... 13

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

SECTION 3

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

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

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

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

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

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

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

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

III. OVENSPECIFICATIONS ................................................. 5

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

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

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

D. Gas Orifice and Pressure Specifications

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

SECTION 4

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

I. MAINTENANCE - DAILY .............................................. 18

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

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

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

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

SECTION 2

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

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

II. INSTALLATIONKIT ........................................................ 8

III.VENTILATIONSYSTEM ................................................. 8

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

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

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

SECTION 5

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

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

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

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ITEM QTY

P/N

DESCRIPTION

55028

55027

59026

STOP,BACKSIDECONVEXT

STOP,SIDEENDCONVEXT

OWNER'SOPERATING&

INSTALLATION MANUAL

42612

33120-0056

22450-0130

59155

KIT,SUPPLEMENTSVCAGENCYLIST

PIPE,BLK 1-1/4" X 54"

BAG,POLY4MIL9"X12"W/MINI-GRIP

BUSHING,HEYCOSB1500-18

Reflector

59099

59098

Bracket, Reflector

59226

WLDMT, Bracket Reflector

Spacer, 1.5" Dia X 1.125" H

SCR, MS HH 10-32 X 1-1/4 18-8

48522

19A15144

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D. STANDOFF INSTALLATION

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

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

2. Repeat procedure for both sides.

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Mount the new reflector bracket to the provided holes on the

front right-hand side of the oven. The reflector should be

positioned just above the conveyor belt.

Using an assistant, hold both back cover switches in the

closed position. This will allow power to the photo-eye, and it

will provide a red beam for aiming. Loosen one of the screws

holding the photo detector gimbal tight, allowing it to be

reaimed at the reflector. The beam should hit exactly in the

center of the reflector, then tighten the screw back down.

Note: This is MUCH easier in reduced light.

Replace all covers.

CONVEYOR BELT REVERSAL

Conveyor belt reversal consists of four steps:

1. Physically reversing the conveyor belt.

2. Moving the lower thermocouple.

3. Resetting direction jumper on the conveyor control board.

4. Switching the photo detector.

REVERSING THE CONVEYOR BELT

Remove the conveyor from the oven and find the master link

location. Remove master links and remove the belt from the

conveyor frame. Reassemble the belt back onto the frame (in

the reverse direction) and reinstall the master links. Replace

the conveyor assembly in the oven.

MOVING THE LOWER THERMOCOUPLE

The lower thermocouple needs to be moved from the lower

outer most hole to the opposite side lower outer most hole.

The thermocouple electrical connection needs to be moved

as well. Insert the thermocouple (TC2) into the thermocouple

hole left open by the removal of the coverplate. Secure the

thermocouple (TC2 and rename TC3) with the two (2) 6-32

screws that were removed previously. Secure the coverplate

with the two (2) 6-32 screws over the hole where the thermo-

couple (TC2) was removed.

RESETTING DIRECTION JUMPER

LocateJumperP1ontheconveyorcontrolboard. Movejumper

from terminals 1 and 2, and replace onto terminals 2 and 3.

Incoming electrical power lines are fed through the strain-

relief fitting, shown in Figure 2-12. The electrical supply

connections are made inside the electrical junction box. The

power lines then connect to the oven circuits through safety

switches located inside the machinery compartment and

each blower motor compartment. These switches interrupt

electrical power to the oven when the Machinery Compart-

ment Access Panel is opened, OR when either of the blower

or rear shrouds is removed.

SWITCHING PHOTO DETECTOR

Removebothrearfanbeltcovers, thenremovethemotorcover

assembly from both sides of the oven. The photo eye is located

on the front side of the left motor bracket. Disconnect the three

connecting wires, noting which color wires assemble to the

associated wires on the photo-detector. Remove the entire

photo detector bracket. Replace the assembly to the right-

hand side of the unit, mirroring the way it was assembled on

the left. Reconnect the detector wiring in the same order it was

on the left.

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Connection

Refer to the wiring diagram inside the machinery compart-

ment of the oven to determine the correct connections for the

electrical supply lines. Connect the supply as indicated on the

wiring diagram.

CAUTION

The terms of the oven's warranty require all start-ups, conver-

sions and service work to be performed by a Middleby Marshall

Authorized Service Agent.

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D. PS870 Propane conversion

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

1. Adjust internal burner air shutters.

2. Replace main Orifices

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

4. Adjust modulating valve bypass settings.

Disconnect the manifold unions closest to the main burner,

and remove the manifold assemblies (four screws each).

Remove the addition four screws holding the burner cores and

slide out each burner core (leaving the ignition and sense

wires connected). Adjust the internal air shutters fully open,

and replace the cores.

Replace the main orifices on the manifold assemblies with the

LP units, and replace the manifold assemblies. Reconnect the

unions. Replace the valve spring with the LP spring, and adjust

the downstream pressure to get 7″ WC.

Adjust the bypass screws in the side of each modulating valve

toapproximately1/6turnfromfullyclosed.Ifthissettingistoolow,

the burners will shut off when trying to modulate. If it is too open,

the unit will tend to gradually raise up in temperature at standby.

Certain safety code requirements exist for the installation of

gas ovens; refer to the beginning of Section 2 for a list of the

installation standards. In addition, because a the oven is

equipped with casters, the gas line connection shall be made

with a connector that complies with the Standard for Connec-

tors 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.).

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

Burner/BlowerMotor

GasBurner

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SECTION3-OPERATION

C. Temperature Control Display

E. Message Bar

Increase

Decrease

A. Main On/Off Button

B. Conveyor Time Setting

D.TEMPSet

Right

Left

LOCATION AND DESCRIPTION OF CONTROLS

C. Temperature Control/Display

A. Main On/Off Button

Displays the set point of both right and left sides of the

oven.

Turnsallovenfunctionsonoroff.Iftheovenisbelowtheset

point, it will rise to the set point and turn the conveyor on.

Ifitisturnedoffandtheovenisabove200°F, theblowers

will remain on until the oven drops below 200° F.

D. TEMP Set

Pressingonthe“TEMP”buttonshowsindividualdisplays

andcombinedadjustments.

B. Conveyor Time Setting

Adjusts and displays the conveyor bake time. Dual belt

ovens have two displays, single units have one.

E. Message Bar

Indicatesvariousmessagespertainingtocurrentoven

conditions.

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NORMAL OPERATION - STEP-BY-STEP-

2. Push the “ON/OFF” button to start the oven. The

A. Main Screen

controller will display the screen, as shown in

Figure 3-3.

1. Whentheunithasbeen“OFF”formorethan1minute

the controller will display the screen saver, as shown

in Figure 3-1. To start operation, push the “Enter/

Reset” button. The controller will display the “OFF”

screen, as shown in Figure 3-2.

ON/OFFbutton

Figure 3-3 Main Screen ON

Figure 3-1 Screen Saver

3. Tochangethetemperature,pushthe“TEMP”button.

The controller will display the screen, shown in

Figure 3-4. To change the left temperature, push the

“←”arrowbutton.Thenpusheitherthe“↑”arrowor“↓”

arrow buttons to increase or decrease temperatures

respectively. To change the right temperature, push

the“→”arrowbutton.Thenpusheitherthe“↑”arrowor

“↓” arrow buttons to increase or decrease tempera-

turesaccordingly.Whenthepropertemperaturesare

entered,pushthe“Enter/Reset”button.Thecontroller

will now show the display shown in Figure 3-3.

Figure 3-2 Main Screen OFF

TEMPSetbutton

Figure 3-4 Temperature Screen

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4. To change the conveyor belt speed, push the “TIME”

button.Thecontrollerwilldisplaythescreen,shownin

Figure3-5.Tochangetheminutesetting,pushthe“←”

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

arrowbuttonstoincreaseordecreasethetimeaccord-

ingly. To change the second setting, push the “→”

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

arrowbuttonstoincreaseordecreasethetimeaccord-

ingly. When the proper times are entered, push the

“ENTER/RESET”button.Thecontrollerwillnowshow

the display shown in Figure 3-3.

C. Daily Shutdown Procedure

1. Makecertaintherearenoproductsleftontheconveyor

in the oven.

2. Press the “ON/OFF” button to turn the oven off.

3. Open the window to allow the oven to cool faster.

4. Aftertheovenhascooledandtheblowershaveturnedoff,

the circuit breaker/fused disconnect may be turned off.

Quick Reference – Touch Screen Controller

A. Main Screen

1. ON/OFF button - Used to turn oven On and Off.

2. TIME - See Separate Instructions.

3. TEMP - See Separate Instructions.

Message Bar

Energy Level Indicators

4. Energylevelindicators-Indicatorstoeithersideofthe

screen indicate the energy input to that side of the

oven.

5. Messagebar-Indicatesvariousmessagespertaining

to current oven conditions.

B. Oven Temperature/Set Point/Indicator Screen

1. Right actual temperature - Indicates current average

temperature of the right side of the oven.

2. Left actual temperature - Indicates current average

temperature of the left side of the oven.

3. Set point temperature - Pressing on this value allows

the user to adjust the set point of the oven.

4. Exit - Returns to the main screen.

C. Energy Modes

ON/OFFbutton

TEMPbutton

TIMEbutton

Energy Mode One - This mode is automatic, and starts

(bake time +1 minute) after the last product has entered

theoven.Inthismode,themainovenblowerswilllowerto

1500RPM,whiletheovenmaintainstemperatureandbelt

speed.

Figure 3-5 Belt Speed Screen

B. Daily Startup Procedure

1. Check that the circuit breaker/fused disconnect is in

theOnposition.Checkthatthewindowisclosed.The

touch panel display should be lit.

2. Adjust the conveyor to the desired bake time.

3. Press the temperature button to display right and left

hand oven settings. Set temperatures as desired.

4. Press the “ON” button to activate the oven. The

conveyor will not run, until the oven temperature has

reached the set points.

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III. QUICK REFERENCE: TROUBLESHOOTING

SYMPTOM

PROBLEM

SOLUTION

Oven will not

turn On.

No electrical power

•

Check that the circuit breaker/fused disconnect is on. Make

sure the emergenct stop button is on.

Oven will not

heat.

No gas pressure

•

Make sure main gas is on.

Burner did not light

Turn oven off, and restart. If it still does not light, call for

service.

Oven is operating, but

little or no air is coming

from the fingers.

Air fingers may be as-

sembled incorrectly after

cleaning.

•

Turn oven off, and allow to cool. Reassemble fingers

correctly.

Conveyor will not move.

Oven is not up to operating

temperature.

Allow oven to preheat.

Conveyor may be jammed.

Turn oven off, and allow to cool. Check conveyor for block-

age.

IV. SCREEN ALERTS

SYMPTOM

PROBLEM

SOLUTION

Battery Symbol in the

lower right hand corner

The internal battery needs

to be replaced to retain

energy mode timings.

•

A qualified service technician should accomplish this.

High Control Compart-

ment Temperature

Clean and replace the

front fan filters.

•

Failure to do this will eventually shut down the oven due to

excessive temperature.

Main Blower problem or

Combustion Blower

problem.

The computer has

detected a problem with

either the main, or burner

blowers.

This should be corrected by a qualified service technician.

Control Over Temp

Front belt jammed

Front filters are clogged

Front belt has stopped

•

Clean or replace filters.

•

Remove obstruction, and restart oven.

If no obstruction, call service.

Rear Belt jammed

High Temp Error

Rear belt has stopped

•

Remove obstruction, and restart oven.

If no obstruction, call service.

Thermocouple or

PLC malfunction

•

Call service

Belt off-Oven not

in temperature

Normal operation until

Oven reaches operating

temperature

Energy Saving Mode 1

Energy saving mode 2

Normal operation

Normal Operation

Energy saving Mode 3

Normal operation

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E. Blower Belts

1. To gain access to each blower belt compartment remove

the four screws shown in Figure 4-8. Then, lift the rear

shroud off its hangers.

If access to the blower motors is required, remove the

three mounting screws (two on the front of each shroud

and one on the rear). Then, lift the end shroud straight up

and off its hangers.

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

3. Check for amount of belt deflection in the center of the belt,

1/2″ deflection is acceptable, see Figure 4-9.

4. If necessary, replace belt.

IV. MAINTENANCE - EVERY 6 MONTHS

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

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

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

electrode assembly.

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

D. Check the conveyor drive shaft bushings and spacers.

Replace the components if they are worn.

Figure 4-9 - Belt Deflection

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ITEM QTY.

P/N

DESCRIPTION

59081

58678

58679

59168

M9608

59337

M9616

57288

57141

50610

54727

M9887

41647

31651

33983

32108

59109

58668

58669

59112

DIGITALDISPLAY,PROGRAMMED

MOTOR,CONVEYORDRIVE

CONVEYORCONTROLBOARD

INVERTER,PROGRAMMED

POWERSUPPLY

KIT,THERMOCOUPLE (6THERMOCOUPLES)

FAN,COOLING

MOTOR,BLOWER

AIRSWITCH BURNER/BLOWER MOTOR

AIRSWITCH MAIN BLOWER

IGNITION MODULE

ASSEMBLY, BURNER BLOWER/MOTOR

VALVE, MODULATING GAS, 1/2"

AMPLIFIER,MODULATINGVALVE

HIGHLIMITCONTROLMODULE,240V

TRANSFORMER,240Vp:24Vs

PLC MODULE,PROGRAMMED

THERMOCOUPLE MODULE

CURRENT MODULE

PHOTOCELL

16, 17, 18

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Wiring Diagrams (electrical schematics)

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