Karcher Oven PS640G User Manual

PS640 Series  
Gas  
Domestic & Std. Export  
ENGLISH  
P/N 60251  
August 2007  
PS640 Series Gas Ovens  
Model:  
• PS640G Gas  
Combinations:  
• Single Oven  
• Double Oven (Two-Stack)  
• Triple Oven (Three-Stack)  
OWNER'S OPERATING AND  
INSTALLATION MANUAL  
for domestic and standard export ovens  
©2007 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  
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Model No.  
Modéle No.  
Serial No.  
Serié No.  
Installation Date  
Date d'installation  
MIDDLEBY MARSHALL  
NO QUIBBLE LIMITED WARRANTY  
(U.S.A. ONLY)  
MIDDLEBY MARSHALL 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’sobligationunderthiswarrantyshallbelimitedtoreplacingor  
repairing, at Seller’s option, without charge, F.O.B. Seller’s factory,  
any part found to be defective and any labor and material expense  
incurred by Seller in repairing or replacing such part. Such warranty  
is limited to a period of one year from date of original installation or  
15 months from date of shipment from Seller’s factory, whichever is  
earlier, providedthattermsofpaymenthavebeenfullymet. Alllabor  
shallbeperformedduringregularworkinghours.Overtimepremium  
will be charged to the Buyer.  
MIDDLEBY MARSHALL, HEREINAFTER REFERRED TO  
AS “THE SELLER”, WARRANTS EQUIPMENT MANUFAC-  
TURED BY IT TO BE FREE FROM DEFECTS IN MATE-  
RIAL AND WORKMANSHIP FOR WHICH IT IS RESPON-  
SIBLE. THE SELLER’S OBLIGATION UNDER THIS WAR-  
RANTY SHALL BE LIMITED TO REPLACING OR REPAIR-  
ING, AT SELLER’S OPTION, WITHOUT CHARGE, ANY  
PART FOUND TO BE DEFECTIVE AND ANY LABOR AND  
MATERIAL EXPENSE INCURRED BY SELLER IN REPAIR-  
ING OR REPLACING SUCH PART. SUCH WARRANTY  
SHALL BE LIMITED TO THE ORIGINAL PURCHASER  
ONLY AND SHALL BE EFFECTIVE FOR A PERIOD OF  
ONEYEAR FROM DATE OF ORIGINAL INSTALLATION, OR  
18 MONTHS FROM DATE OF PURCHASE, WHICHEVER  
IS EARLIER, PROVIDEDTHATTERMS OF PAYMENT HAVE  
BEEN FULLY MET.  
Thiswarrantyisnotvalidunlessequipmentisinstalled,started,  
and demonstrated under the supervision of a factory-autho-  
rized installer.  
Normal maintenance functions, including lubrication, adjustment of  
airflow,thermostats,doormechanisms,microswitches,burnersand  
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.  
Anyrepairsorreplacementsofdefectivepartsshallbeperformedby  
Seller’s authorized service personnel. Seller shall not be respon-  
sible for any costs incurred if the work is performed by other than  
Seller’s authorized service personnel.  
Normal maintenance functions, including lubrication, clean-  
ing, or customer abuse, are not covered by this no quibble  
warranty.  
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  
personnel. Authorized service agencies are located in prin-  
cipal 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 particu-  
lar 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, in-  
cluding 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’ssoleandexclusiveremedyforanyaction, whetherinbreach  
of contract or negligence. In no event shall seller be liable for a sum  
in excess of the purchase price of the item.  
© 2003 - Middleby Marshall, A Middleby Company.  
The Middleby Marshall logo is a registered trademark of Middleby Marshall, A Middleby Company.  
Middleby Marshall Inc. • 1400 Toastmaster Drive • Elgin, Illinois 60120-9272 U.S.A. • (847) 741-3300 • FAX: (847) 741 4406  
iii  
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TABLE OF CONTENTS  
Page  
Page  
SECTION 1 – DESCRIPTION ............................................ 1  
I. OVEN USES ............................................................ 1  
II. OVEN COMPONENTS ............................................ 1  
A. Conveyor Motor Drive ................................... 1  
B. Crumb Pans .................................................. 1  
C. Conveyor....................................................... 1  
D. End Plugs...................................................... 1  
E. Eyebrows ...................................................... 1  
F. Window ......................................................... 1  
G. Machinery Compartment Access Panel ........ 1  
H. Serial Plate.................................................... 1  
I. Control Panel ................................................ 1  
J. Photo Cell ..................................................... 1  
K. Gas Burner.................................................... 1  
L. Blowers ......................................................... 1  
M. Air Fingers..................................................... 1  
III. OVEN SPECIFICATIONS ........................................ 2  
A. Dimensions ................................................... 2  
B. General Specifications .................................. 2  
C. Electrical Specifications for  
SECTION 3 – OPERATION .............................................. 14  
I. LOCATION AND DESCRIPTION OF CONTROLS 16  
II. NORMAL OPERATION, STEP-BY-STEP ................ 17  
A. Main Screen ................................................ 17  
B. Daily Startup Procedure .............................. 18  
C. Daily Shutdown Procedure ......................... 18  
III. QUICK REFERENCE: TROUBLESHOOTING ...... 19  
IV. SCREEN ALERTS ................................................. 19  
SECTION 4 – MAINTENANCE ........................................ 20  
I. MAINTENANCE – DAILY....................................... 20  
II. MAINTENANCE – MONTHLY ............................... 21  
III. MAINTENANCE – EVERY 3 MONTHS ................. 22  
IV. MAINTENANCE – EVERY 6 MONTHS ................ 23  
V. KEY SPARE PARTS KIT ....................................... 24  
SECTION 5 – ELECTRICAL WIRING DIAGRAM............ 25  
I. WIRING DIAGRAM, 640 GAS OVEN, 208/240V,  
50/60 Hz, 1 Ph ....................................................... 25  
PS640 Gas Ovens ........................................ 2  
D. Gas Orifice and Pressure Specifications  
for PS640 Gas Ovens ................................... 2  
SECTION 2 – INSTALLATION........................................... 3  
I. BASE PAD KIT......................................................... 4  
II. INSTALLATION KIT ................................................. 5  
III. VENTILATION SYSTEM .......................................... 8  
A. Requirements................................................ 8  
B. Recommendations ........................................ 8  
C. Other Ventilation Concerns ........................... 8  
IV. ASSEMBLY .............................................................. 9  
A. Base Pad, Legs, Casters .............................. 9  
B. Stacking ....................................................... 10  
C. Restraint Cable Installation ......................... 10  
D. Conveyor Installation .................................. 11  
E. Standoff Installation .................................... 11  
V. FINAL ASSEMBLY................................................. 12  
VI. ELECTRICAL SUPPLY .......................................... 12  
Connection ....................................................... 13  
VII. GAS SUPPLY ........................................................ 13  
A. Gas Utility Rough-In Recommendations ..... 13  
B. Connection .................................................. 14  
C. Gas Conversion .......................................... 14  
D. Propane Conversion ................................... 14  
E. Adjusting the Maximum Pressure Setting ... 14  
F. Adjusting the Minimum Pressure Setting .... 15  
G. Checkout ..................................................... 15  
H. Maintenance ............................................... 15  
NOTE  
Wiring Diagrams are in Section 5 of this Manual.  
The diagram for each oven is also on the lower  
inner surface of its Control Console.  
iv  
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SECTION 1 – DESCRIPTION  
Figure 1-1. Oven Components  
I. OVEN USES  
PS640 Series 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.  
E
D
J
I
G
II. OVEN COMPONENTS – see Figure 1-1.  
A. Conveyor Drive Motor: Moves the conveyor.  
B. Crumb Pans: Catch crumbs and other materials that drop  
through the conveyor belt. One crumb pan is located at  
each end of the conveyor.  
C. Conveyor: Moves the food product through the oven.  
D. End Plugs: Allow access to the oven’s interior.  
F
H
E. Eyebrows: Can be adjusted to various heights to prevent  
A
heat loss into the environment.  
F. Window: Allows the user to access food products inside  
the baking chamber.  
C
G. Machinery Compartment Access Panel: Allows access  
to the oven’s interior and control components. No user  
serviceable parts are located in the machinery compart-  
ment.  
B
H. Serial Plate: Provides specifications for the oven that  
affect installation and operation. Refer to Section 2, Instal-  
lation for details.  
I. Control Panel: Location of the operating controls for the  
oven. Refer to Section 3, Operation, for details.  
J. Photo Cell: Turns oven On when beam is interrupted.  
Not Shown:  
K. Gas Burner (gas ovens): Heat air, which is then projected  
to the air fingers by the blowers.  
L. Blowers: Projecthotairfromtheburnerorheatingelement  
to the air fingers.  
M. Air Fingers: Project streams of hot air onto the food  
product.  
1
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I. OVEN SPECIFICATIONS  
Table 1-1 Dimensions  
Overall Height  
Single Oven  
Double Oven  
Triple Oven  
48-3/16(1219mm)  
60(1524mm)  
62-3/4(1575mm)  
60(1524mm)  
78-11/16(1981mm)  
60(1524mm)  
Overall Depth  
Overall Length  
76-1/2(1930mm)  
76-1/2(1930mm)  
76-1/2(1930mm)  
Conveyor Width – belt width is 32″  
33-1/2(838mm)  
or 2 × 15(381mm)  
33-1/2(838mm)  
or 2 × 15(381mm)  
33-1/2(838mm)  
or 2 × 15(381mm)  
Recommended Minimum Clearances  
Rear of Oven to Wall  
3(76mm)  
3(76mm)  
3(76mm)  
Control end of conveyor to Wall  
Non-control end of conveyor to Wall)  
1(25.4mm)  
1(25.4mm)  
1(25.4mm)  
1(25.4mm)  
1(25.4mm)  
1(25.4mm)  
Table 1-2: General Specifications  
PS640 GAS  
Weight  
1150 lbs. (522kg)  
Rated Heat Input  
120,000 BTU (31,500kcal, 37 kW/hr)  
600°F / 315°C  
Maximum Operation Temperature  
Air Blowers  
Two Blowers at 1900 RPM  
15 min.  
Warmup Time  
Table 1-3: Electrical specifications for PS640G gas ovens  
Main Blower  
Voltage  
Control Circuit  
Voltage  
Phase  
Freq  
Current  
Draw  
Poles  
Wires  
208-240VAC  
208-240VAC  
1Ph  
50/60Hz  
11-9.6 Amp  
2 Pole  
3 Wire (2 hot, 1 gd)  
Table 1-4: Gas orifice and pressure specifications for PS640G gas ovens  
Gas  
Type  
Main Orifice I.D.  
PS640G  
Supply (Inlet)  
Pressure  
Orifice (Manifold)  
Bypass  
Pressure  
Pressure  
Natural  
0.120  
6-12W.C. (14.9 - 29mbar)  
3.5W.C. (8.7mbar)  
10.0W.C. (24.9mbar)  
0.2W.C. (0.015 mbar)  
0.5W.C. (0.12 mbar)  
Propane  
1.9mm  
11-14W.C. (27.4 - 34.9mbar)  
IMPORTANT – Additional electrical information is provided on the oven’s serial plate, and on the wiring diagram  
inside the machinery compartment.  
GAS ORIFICE AND PRESSURE SPECIFICATIONS (PER OVEN CAVITY) - CE OVENS  
Supply (Inlet) Pressure  
IT,PT,ES,SE,  
Main  
Orifice  
dia.  
UK,CH,IT,AT,  
DK,FI  
I2H  
SE,CH,AT,DK,  
FI,DE,NL  
I3B/P  
BE,IE,IT,PT,  
ES,UK  
I3+  
Orifice  
(Manifold)  
Pressure  
Rated  
Heat  
Input  
Gas  
Type  
NL  
I2L  
DE  
I2E  
BE,FR  
I2E+  
G20  
G25  
G30  
0.120  
20  
mbar  
--  
20  
mbar  
20  
mbar  
--  
--  
--  
--  
11.21  
mbar  
22.36  
kW-hr.  
(3.05 mm)  
0.120″  
(3.05 mm)  
--  
25  
mbar  
--  
--  
16.19  
mbar  
22.36  
kW-hr.  
0.075″  
(1.9 mm)  
--  
--  
--  
--  
29 or 50  
mbar  
28-30, 37  
or 50 mbar  
26.2  
mbar  
22.59  
kW-hr.  
NOTE  
Wiring Diagrams are contained in Section 5 of this Manual  
and are also located inside the oven at the  
bottom of the Control Panel.  
Additional electrical information is provided on the oven's serial plate.  
This Manual Must Be Kept For Future Reference  
2
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SECTION 2 – INSTALLATION  
WARNING – After any conversions, readjustments, or service work on the oven:  
• Perform a gas leak test.  
• Test for proper combustion and gas supply.  
• Test for correct air supply, particularly to the • Check that the ventilation system is in operation.  
burner blower.  
WARNING - Keep the appliance area free and clear of combustibles.  
WARNING – The oven must be installed on an even (level) non-flammable flooring and any adjacent walls  
must be non-flammable. Recommended minimum clearances are specified in the Description section of  
this manual.  
WARNING – Do not obstruct the flow of combustion and ventilation air to and from your oven. There must  
be no obstructions around or underneath the oven. Constructional changes to the area where the oven  
is installed shall not affect the air supply to the oven.  
CAUTION: To reduce the risk of fire, the appliance is to be mounted on floors of noncombustible construction with  
noncombustible flooring and surface finish and with no combustible material against the underside thereof, or on  
noncombustible slabs or arches having no combustible material against the underside thereof, such construction  
shall in all cases extend not less than 12 inches (304mm) beyond the equipment on all sides.  
CAUTION: For additional installation information, contact your local Authorized Service Agent.  
NOTETheremustbeadequateclearancebetweentheovenandcombustibleconstruction. Clearancemustalso  
be provided for servicing and for proper operation.  
NOTE – An electrical wiring diagram for the oven is located inside the machinery compartment.  
NOTE: All aspects of the oven installation, including placement, utility connections, and ventilation requirements,  
mustconformwithanyapplicablelocal, national, orinternationalcodes. Thesecodessupersedetherequirements  
and guidelines provided in this manual.  
NOTE: In the USA, the oven installation must conform to local codes. In the absence of local codes, gas oven  
installations must conform with the National Fuel Gas Code, ANSI Z223.1. Gas and electric ovens, when installed,  
must be electrically grounded in accordance with local codes, or in the absence of local codes, with the National  
Electrical Code (NEC), or ANSI/NFPA70.  
NOTE: In Canada, the oven installation must conform with local codes. In the absence of local codes, gas  
oven installations must conform with the Natural Gas Installation Code, CAN/CGA-B149.1, or the Propane Gas  
Installation Code, CAN/CGA-B149.2, as applicable. Gas and electric ovens, when installed, must be electrically  
grounded in accordance with local codes, or in the absence of local codes, with the Canadian Electrical Code  
CSA C22.2.  
3
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PS640 OVEN INSTALLATION  
REQUIRED KITS AND EQUIPMENT  
PS640  
Gas Oven  
Installation  
Kit  
PS640  
Single Oven  
Option Base w/  
15Legs,  
Casters & Top  
Kit  
PS640  
DoubleOven  
OptionBase w/  
6Legs,  
Casters & Top  
Kit  
PS640  
TripleOven  
OptionBase w/  
Casters& Top  
Kit  
TYPE OF INSTALLATION  
P/N51100  
P/N59720  
P/N59725  
P/N59726  
PS640 Single Gas Oven  
PS640 Double Gas Oven  
PS640 Triple Gas Oven  
1
2
3
1
1
1
PARTS LIST FOR SERIES PS640 GAS OVEN  
INSTALLATION KIT  
P/N 51100  
(Two required for double oven)  
(Three required for triple oven)  
ITEM  
NO.  
QTY  
PART NO.  
22361-0001  
55028  
DESCRIPTION  
1
2
3
4
5
6
1
1
1
1
1
1
FLEXIBLE GAS HOSE  
CONVEYOR END STOP  
55027  
CONVEYOR LEFT REAR STOP  
SERVICE AGENCY DIRECTORY  
LABEL, MM  
42612  
22500-0080  
51054  
ASSY, HANDLE & DOOR  
Figure 2-1. PS640-Series Gas Oven Installation Parts  
2
3
1
6
5
4
4
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Figure 2-2. Model PS640 Single Oven  
Option Base with Legs and Top  
1
8
HARDWARE BAG  
5, 6, 7, 10 & 11  
3
4
2
9
PARTS LIST FOR PS640 SERIES SINGLE OVEN OPTION - BASE w/15LEGS & TOP  
P/N 59720  
ITEM NO.  
QTY  
PART NO.  
DESCRIPTION  
1
1
60287  
COMPLETE BASE WELDMENT  
2
3
4
2
37900-0024  
22290-0009  
22290-0010  
220373  
TOP PLATE, LEG WELDMENT  
SWIVEL CASTER W/BRAKE FLAT PLATE  
SWIVEL CASTER FLAT PLATE  
3/8-16 × 1HEX SCREW, SST  
3/8FLAT WASHER, SS  
4
2
5
32  
32  
32  
1
6
21416-0001  
21422-0001  
22450-0228  
59560  
7
3/8SPLIT LOCK WASHER, ZP  
RESTRAINT CABLE ASSEMBLY  
TOP COVER  
8
9
1
10  
11  
2
59677  
SCR, MS SL TR HD 10-32 × 2-1/2″  
SCR, MS STR TRSHD 10-32 × 3/4″  
2
7A2S15  
5
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Figure 2-3. Model PS640 Double Oven  
Option Base with Legs and Top  
1
8
HARDWARE BAG  
5, 6, 7, 10 & 11  
3
4
2
9
PARTS LIST FOR PS640 SERIES DOUBLE OVEN OPTION - BASE w/6LEGS & TOP  
P/N 59725  
ITEM NO.  
QTY  
PART NO.  
DESCRIPTION  
1
1
60287  
COMPLETE BASE WELDMENT  
2
3
4
2
37900-0102  
22290-0009  
22290-0010  
220373  
TOP PLATE, LEG WELDMENT  
SWIVEL CASTER W/BRAKE FLAT PLATE  
SWIVEL CASTER FLAT PLATE  
3/8-16 × 13 HEX SCREW, SST  
3/8FLAT WASHER, SS  
4
2
5
32  
32  
32  
1
6
21416-0001  
21422-0001  
22450-0228  
59560  
7
3/8SPLIT LOCK WASHER, ZP  
RESTRAINT CABLE ASSEMBLY  
TOP COVER  
8
9
1
10  
11  
2
59677  
SCR, MS SL TR HD 10-32 × 2-1/2″  
SCR, MS STR TRSHD 10-32 × 3/4″  
2
7A2S15  
6
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Figure 2-4. Model PS640 Triple Oven  
Option Base with Outriggers and Top  
1
15  
HARDWARE BAG  
3
7, 8, 9, 10, 11, 12,  
13, 14, & 17  
5
4
6
2
16  
PARTS LIST FOR PS640 SERIES TRIPLE OVEN OPTION - BASE w/CASTERS & TOP  
P/N 59726  
ITEM NO.  
QTY  
PART NO.  
DESCRIPTION  
1
1
60287  
COMPLETE BASE WELDMENT  
2
3
4
2
45209  
22290-0009  
22290-0010  
45206  
QUAD OUTRIGGER WELDMENT  
SWIVEL CASTER, W/BRAKE FLAT PLATE  
SWIVEL CASTER, FLAT PLATE  
INSERT,QUAD ADJUSTMENT FOOT  
SPACER,QUAD CASTER  
4
2
5
4
6
4
45205  
7
32  
32  
32  
16  
8
A27727  
3/83 -16x1-1/4 HEX BOLT  
8
A21924  
3/83 FLAT WASHER, SS  
9
21422-0001  
21172-0004  
2001048  
A27750  
3/83 SPLIT LOCK WASHER, ZP  
3/83 -16 NYLON INSULATED LOCKNUT, ZC  
1/23 -13 x 1-3/8 18-8 HEX CAPSCREW  
1/23 18-8 FLAT WASHER  
10  
11  
12  
13  
14  
15  
16  
17  
8
8
21422-0016  
59677  
1/23 18-8 LOCK WASHER  
2
SCR, MS SL TR HD 10-32X2-1/2  
RESTRAINT CABLE ASSEMBLY  
TOP COVER  
1
22450-0228  
59560  
1
2
7A2S15  
SCR, MS STR TRSHD 10-32X3/4″  
7
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B. Recommendations  
III. VENTILATION SYSTEM  
NOTE THAT THE HOOD DIMENSIONS SHOWN IN  
FIGURE 2-5 ARE RECOMMENDATIONS ONLY.  
LOCAL, NATIONAL AND INTERNATIONAL CODES  
MUST BE FOLLOWED WHEN INSTALLING THE  
VENTILATION SYSTEM. ANY APPLICABLE CODES  
SUPERSEDE THE RECOMMENDATIONS SHOWN IN  
THIS MANUAL.  
IMPORTANT  
Where national or local codes re-  
quire the installation of fire sup-  
pression equipment or other  
supplementary equipment, DO NOT  
mount the  
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.  
equipment directly to the oven.  
To avoid a negative pressure condition in the kitchen area,  
return air must be brought back to replenish the air that was  
exhausted. A negative pressure in the kitchen can cause heat-  
related problems to the oven components as if there were no  
ventilation at all. The best method of supplying return air is  
through the heating, ventilation and air conditioning (HVAC)  
system. Through the HVAC system, the air can be tempera-  
ture-controlled for summer and winter. Return air can also be  
brought in directly from outside the building, but detrimental  
effectscanresultfromextremeseasonalhotandcoldtempera-  
tures from the outdoors.  
MOUNTING SUCH EQUIPMENT ON  
THE OVEN MAY:  
• VOID AGENCY CERTIFICATIONS  
• RESTRICT SERVICE ACCESS  
• LEAD TO INCREASED SERVICE  
EXPENSES FOR THE OWNER  
A. Requirements  
NOTE: Return air from the mechanically driven system must  
not blow at the opening of the baking chamber. Poor  
oven baking performance will result.  
CAUTION: Gas oven installations REQUIRE a mechani-  
cally driven ventilation system with electrical  
exhaust air sensing control.  
C. Other ventilation concerns  
Special locations, conditions, or problems may require  
the services of a ventilation engineer or specialist.  
A mechanically driven ventilation system is STRONGLY  
RECOMMENDED for electric oven installations.  
Inadequate ventilation can inhibit oven performance.  
PROPER VENTILATION OF THE OVEN IS THE RESPONSI-  
BILITY OF THE OWNER.  
It is recommended that the ventilation system and duct  
workbecheckedatprevailingintervalsasspecifiedbythe  
hood manufacturer and/or HVAC engineer or specialist.  
Figure 2-5. Ventilation System  
18(458mm)  
minimum  
(Typical - both  
ends of oven)  
3(76mm)  
minimum  
2(51mm)  
minimum  
8(203mm)  
minimum  
8
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Figure 2-6. Leg extension and casters installation  
IV. ASSEMBLY  
A. Top Panel and Base Pad Assembly  
Finished sides of  
leg extension face  
corner of base  
pad  
1. Install the four leg extensions onto the base pad using  
the 3/8-16 × 1screws, 3/8flat washers, and  
3/8lockwashers supplied in the Base Pad Kit. See  
Figure 2-6. Check that the finished sides of each leg  
extension face OUTWARDS. One rear leg should be  
attached using three 3/8-16 × 1screws and the 3/4″  
eyebolt, as shown in Figure 2-6. This eyebolt acts as the  
anchor point for the restraint cable assembly (see Part C,  
Restraint Cable Installation).  
2. If your oven is equipped with the lower shelf, position it in  
place as shown in Figure 2-6. Check that the lip on the  
shelf faces DOWN. Seal joint between leg and shelf with  
NSF listed silicone.  
3. Install one caster onto each leg extension, as shown in  
Figure 2-7. Use the 3/8-16 × 1screws, 3/8flat wash-  
ers, and 3/8lockwashers supplied in the Installation Kit.  
The locking casters should be installed at the FRONT of  
the oven. The non-locking casters should be installed at  
the REAR of the oven.  
Domestic and  
standard export  
ovens:  
Lower  
shelf  
Locking casters -  
FRONT of oven  
4. Install the lower oven cavity onto the base pad.  
See Fig 2-7.  
Non-locking casters -  
REAR of oven  
5. For single ovens ONLY:  
3/8flat  
Install the top panel using the screws included in the base  
pad kit, as shown in Figure 2-8. Then, skip ahead to Part  
C, Restraint Cable Installation.  
washer  
3/8lock  
washer  
For double or triple ovens:  
3/8-16 × 1″  
hex screw  
Continue on to Part B, Stacking. Note that the top panel  
should NOT be installed for double and triple ovens until  
after stacking the oven cavities.  
Figure 2-7. Base pad Installation  
Figure 2-8. Top panel installation  
Bottom oven•  
cavity  
#10-32 × 2-1/2″  
Top  
screw length  
panel  
#10-32 × 3/4″  
screw length  
Assembled•  
base pad  
9
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C. Restraint Cable Installation  
NOTE: DO NOT install top panel onto double or triple  
ovens until AFTER stacking the oven cavities. See  
Part B, Stacking.  
Because the oven is equipped with casters, a restraint cable  
assembly must be installed to limit the movement of the appli-  
ance without depending on the connector and the quick discon-  
nect device or its associated piping. One end of the cable is  
anchored to the eyebolt on the rear surface of the oven’s base  
pad, while the other is anchored to the wall. See Figure 2-11.  
B. Stacking  
For single ovens, skip ahead to Part C, Restraint Cable  
Installation.  
After connecting the restraint cable, move the oven to its final  
location. Adjust the bottom (hex) sections of the feet so that  
the casters are off the floor. For quad ovens, lock the two  
front casters.  
IMPORTANT  
Middleby Marshall STRONGLY RECOMMENDS that PS640  
Gas oven cavities be stacked BY AUTHORIZED PERSONEL.  
Contact your Middleby Marshall Authorized Service Agent for  
complete stacking instructions.  
Figure 2-10. Top panel installation  
1. Stack an oven cavity on top of the lower oven. Check  
the following:  
#10-32 × 3/4  
Top  
screws  
panel  
• All four sides of the lower lip (on the bottom edge  
oftheovencavity)overlapthetopoftheloweroven  
#10-32 × 2-1/2″  
screws  
• The oven is level  
• The oven is firmly seated  
See Figure 2-9.  
2. For triple ovens, repeat Step 1 to install the top  
oven cavity.  
3. Install the top panel using the screws included in the base  
pad kit, as shown in Figure 2-10.  
Figure 2-9. Stacking  
Figure 2-11. Installing the Restraint Cable  
Restraint cable assembly  
3/8-18 × 1″  
eyebolt on  
rear leg  
extension  
3/4(19mm)  
eyebolt  
Wall of structure  
10  
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D. Conveyor Installation  
Figure 2-13. Conveyor placement  
1. UnfoldtheconveyorasshowninFigure2-12. Then, begin  
to slide the conveyor into the end of the oven. The  
conveyor can only be installed from the end of the oven  
with the drive motor.  
Crumb tray  
support  
2. 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 under-  
side of the conveyor frame rest firmly against the lower  
end plugs, as shown in Figure 2-13.  
bracket  
End plug  
3. When the conveyor is positioned properly, check for  
freedom of movement of the conveyor belt by pulling it for  
about 2-3 feet (0.6-1.0m) with your fingers. The drive and  
idler shafts must rotate smoothly, and the belt must move  
freely without rubbing on the inside of the oven.  
4. Check the tension of the conveyor belt as shown in  
Figure 2-14. The belt should lift about 1(25mm).  
DO NOT OVERTIGHTEN THE CONVEYOR BELT.  
Conveyor  
placed in  
oven  
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 2-14.  
Figure 2-12. Conveyor installation  
Folded  
frame  
Figure 2-14. Conveyor Belt tension  
Idler end (with belt tension  
adjustment screws)  
1(25mm)  
vertical  
deflection  
Adjustment  
screws (2) on  
idler end of  
conveyor  
Drive end (with  
drive sprocket)  
11  
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5. 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:  
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  
thereversedirection)andreinstallthemasterlinks.Replacethe  
conveyor assembly in the oven.  
• Remove the conveyor assembly from the oven and  
place it flat on the floor.  
RESETTING DIRECTION JUMPER  
• Remove the master links using long-nose pliers. Then,  
roll up the belt along the length of the conveyor frame.  
Locate Jumper P1 on the conveyor control board. Move jumper  
from terminals 1 and 2, and replace onto terminals 2 and 3.  
• Add or remove belt links as necessary to achieve the  
correct belt tension.  
CAUTION: Shock hazard in compartments electrical filters  
• Replace the belt on the conveyor frame. Check that the  
conveyorbeltlinksareorientedasshowninFigure2-15,  
and that the smooth side of the conveyor belt faces UP.  
are electrically alive.  
• Connect the inside master links. Check that the links are  
oriented as shown in Figure 2-15.  
SWITCHING PHOTO DETECTOR  
CAUTION: Disconnect Power Before Switching Photo eye.  
• 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 2-15.  
Remove the three screws securing the access door to the unit.  
Open the access door and disconnect the connector fitting to  
the photo eye assembly. Remove the two screws securing the  
photo eye assembly to the control box. Remove the four nuts  
securingthephotoeyetothehousing.Rotatethephotoeye180  
degrees and resecure the photo eye with the four nuts.  
• Replace the conveyor into the oven.  
Figure 2-15. Conveyor and Master Link orientation  
Direction  
of travel  
CORRECT  
master link  
position  
Ontheoppositecontrolbox, removethetwoscrewsholdingthe  
cover where the photo eye assembly will be positioned. Secure  
the photo eye assembly in position with the two screws. Place  
the photo eye cover on the opposite control box, where the  
photo eye assembly was removed, and secure the two screws.  
Secure the access door with the three screws.  
Incorrect  
master link  
position  
Remove the three screws securing the access door on the  
opposite side. Open the access door, where the photo eye is  
now positioned, and connect the photo eye connector fitting.  
Secure the access door with the three screws.  
E. Final Assembly  
1. Installthecrumbtraysunderneaththeconveyorasshown  
in Figure 2-16.  
Apply power to the unit. Adjust the photo eye height by loosen-  
ingthetwoscrewssecuringthephotoeyeassemblyandsliding  
the photo eye assembly either up or down, such that the beam  
is approximately 1/4 inch above the belt.  
Figure 2-16. Crumb Trays  
Note: This is MUCH easier in reduced light.  
Replace all covers.  
VI. ELECTRICAL SUPPLY  
WARNING: Authorized installation personnel normally  
accomplish the connections for the ventila-  
tion system, electric supply, and gas supply,  
asarrangedbythecustomer.Followingthese  
connections, the factory-authorized installer  
can perform the initial startup of the oven.  
Crumb tray  
insertion  
NOTE: The electric supply installation must satisfy the re-  
quirements of the appropriate statutory authority such  
as the National Electrical Code, CSA C22.2; the Aus-  
tralian Code AG601; or other applicable regulations.  
CONVEYOR BELT REVERSAL  
Conveyor belt reversal consists of three steps:  
1. Physically reversing the conveyor belt.  
2. Resetting direction jumper on the conveyor control board.  
3. Switching the photo detector.  
NOTE: The electric supply connection must meet all national  
and local electrical code requirements.  
Check the oven serial plate before making any electric supply  
connections. Electric supply connections must agree with data  
12  
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Figure 2-17. Utility Connection Locations for Gas Ovens  
Strain-relief  
fitting  
Gas Inlet  
(One per Single, Double,  
or Triple Oven)  
Electrical Junction Box  
(One per oven cavity)  
ontheovenserialplate.Thelocationoftheserialplateisshown  
in Figure 1-1 (in Section 1, Description).  
VII. GAS SUPPLY  
CAUTION: DURINGPRESSURETESTINGNOTEONEOF  
A fused disconnect switch or a main circuit breaker (customer  
furnished) MUST be installed in the electric supply line for each  
oven cavity. It is recommended that the switch/circuit breaker  
have Lockout/Tagout capability.  
THE FOLLOWING:  
1. The oven and its individual shutoff valve must be discon-  
nected from the gas supply piping system during any  
pressure testing of that system at test pressure in excess  
of ½ psi (3.45 kPa).  
The supply conductors must be of the size and material  
(copper) recommended. Refer to the wiring diagram inside the  
machinery compartment of the oven. Electrical specifications  
are also listed on the oven’s serial plate and in Table 1-3,  
Electrical Specifications (in Section 1, Description).  
2. Theovenmustbeisolatedfromthegassupplypipingsystem  
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 ½ psi (3.45 kPa).  
The oven requires a ground connection to the oven ground  
screw. For gas ovens, the screw is located in the electrical  
junction box (see Figure 2-14). If necessary, have the electri-  
cian supply the ground wire. Do NOT use the wiring conduit or  
other piping for ground connections.  
3. If incoming pressure is over 14W.C. (35mbar),  
a separate regulator MUST be installed in the line BE-  
FORE the individual shutoff valve for the oven.  
Incoming electrical power lines are fed through the strain-relief  
fitting, shown in Figure 2-14. 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 Compartment Access Panel is  
opened, OR when the rear panel is removed.  
WARNING: To prevent damage to the control valve regu-  
lator during initial turn-on of gas, it is very  
important to open the manual shutoff valve  
very slowly.  
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.  
Connection  
Refer to the wiring diagram inside the machinery compartment  
of the oven to determine the correct connections for the  
electrical supply lines. Connect the supply as indicated on the  
wiring diagram.  
A. Gas Utility Rough-In Recommendations  
The following gas system specifications are STRONGLY  
RECOMMENDED. Deviating from these recommendations  
may affect the baking performance of 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.  
Gas Meter  
• One or two cavities: 750 cfh meter  
• Three oven cavities: 1200 cfh meter  
Gas Line  
• DEDICATED LINE from the gas meter to the oven  
• 2(50.8mm) pipe for natural gas  
• 2(50.8mm) pipe for propane  
• Maximum length: 2002 (61m). Each 90°elbow  
equals 7(2.13m) of pipe.  
13  
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B. Connection  
Figure 2-18. Flexible Gas Hose Installation  
Check the oven’s gas supply requirements before making the  
gas utility connection. Gas supply requirement are listed on the  
oven’s serial plate and in Table 1-4. Gas Orifice and Pressure  
Specifications (in Section 1, Description).  
1/2gas  
pipe nipple  
3/4-1/2″  
gas pipe  
reducer  
Check the serial plate to determine the type of gas (Propane or  
Natural) to be used with the oven.  
To Gas  
Supply  
Pipe  
Refer to the instructions in the gas hose package (included  
in the Installation Kit) before connecting the gas line. One  
gas line connection method is shown in Figure 2-18;  
however, compliance with the applicable standards and  
regulations is mandatory.  
3/4gas  
pipe nipple  
1/2gas line  
tee with  
90°  
Elbow  
pressure tap  
Inlet, regulated, and pilot gas pressure readings can be  
taken using a digital tube manometer at the tap location shown  
in Figure 2-19. Figure 2-19 shows the burner assembly and  
Figure 2-21 shows the gas valve.  
Full-Flow  
Gas  
Shutoff  
Valve  
NOTE: The installation must conform with local codes or in the  
absence of local codes, with the National Fuel Gas  
Code, ANSI Z223.1-latest edition.  
Individual gas  
connection for  
each oven  
cavity  
Flexible  
Gas Hose  
Quick-  
disconnect  
device  
Certain safety code requirements exist for the installation of gas  
ovens;refertothebeginningofSection2foralistoftheinstallation  
standards. In addition, because the oven is equipped with cast-  
ers, the gas line connection shall be made with a connector that  
complies with the Standard for Connectors for Movable Gas  
Appliances, ANSI Z21.69 (in U.S.A.), as well as a quick-discon-  
nectdevicethatcomplieswiththeStandardforQuick-Disconnect  
Devices for Use With Gas Fuel, ANSI Z21.41 (in U.S.A.).  
Figure 2-19. Gas Burner Assembly  
Gas Burner  
C. Gas Conversion  
Where permitted by local and national codes, it is possible to  
convert ovens from natural to propane gas, or from propane to  
natural gas. Use the appropriate Middleby Gas Conversion Kit  
for the specific oven model.  
CAUTION: The terms of the oven’s warranty require all start-  
ups, conversions and service work to be per-  
formed by a Middleby Authorized Service Agent.  
D. PS640 Propane Conversion  
Two items have to be changed, to change the oven to LP:  
1. Replace main orifices.  
Manifold Pressure Tap  
2. Adjust main gas regulator per instructions below.  
3. Make sure that the appliance is in operation and the  
Moduplus® coil is energized with maximum current.  
Disconnect the manifold union closest to the main burner, and  
remove the manifold assembly (four screws). Slide out the  
manifold assembly (leaving the ignition and sense wires con-  
nected). Replace the main orifices.  
4. If maximum rate pressure needs adjustment, use an 8 mm  
wrench to turn adjustment screw for maximum pressure  
setting (clockwise to increase or counter-clockwise to  
decrease pressure), until the desired maximum outlet  
pressure is obtained.  
Replace the main orifices on the manifold assemblies with the LP  
units, and replace the manifold assembly. Reconnect the union.  
E. Adjusting the Maximum Pressure Setting  
5. Disconnect electrical connection of the Moduplus®.  
1. Disconnect pressure feedback connection (if appcable).  
6. Check minimum pressure setting and readjust if neces-  
sary. (See Adjusting Minimum Pressure Setting for  
proper adjusting procedure.)  
2. Connect a suitable pressure gauge to pipe line or to  
outlet pressure tap of gas control concerned, to mea-  
sure burner pressure (measuring point must be as near  
to burner as possible).  
7. Reconnect pressure feedback connection (if appcable).  
8. If minimum and maximum pressures are set, wire the  
Moduplus® in circuit.  
9. Close pressure tap screw.  
14  
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F. Adjusting the Minimum Pressure Setting  
Figure 2-20. Burner Assembly  
1. Disconnect pressure feedback connection (if appcable).  
2. Connect a suitable pressure gauge to pipe line or to outlet  
pressure tap of gas control concerned, to measure burner  
pressure (measuring point must be as near to burner as  
possible).  
Gas  
Valve  
3. Disconnect electrical connection of the Moduplus®.  
4. Energize operator, set control in operation and wait until  
an outlet pressure is recorded on pressure gauge.  
5. If minimum rate pressure needs adjustment, use an 8 mm  
wrench to turn adjustment screw for minimum pressure  
setting (clockwise to increase or counter-clockwise to  
decrease pressure), until the desired minimum outlet  
pressure is obtained.  
6. Check if main burner lights easily and reliable at minimum  
pressure.  
7. Reconnect pressure feedback connection (if appcable).  
8. Close pressure tap screw.  
G. Checkout  
After any adjustment, set appliance in operation and observe  
through a component cycle to ensure that burner system  
components function correctly.  
Main•  
Pressure•  
Tap  
Main•  
Orifices  
Manifold  
Assembly  
H. Maintenance  
It is recommended to check yearly the minimum and the  
maximum setting and readjust them if necessary.  
Figure 2-21. Gas Valve  
Adjustment Screw (5 mm)  
for minimum pressure  
setting  
Adjustment Screw  
(8 mm) for  
maximum  
pressure  
setting  
15  
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SECTION 3 - OPERATION  
C. Temperature Control Display  
E. Message Bar  
Increase  
Decrease  
A. Main On/Off Button  
B. Conveyor Time Setting  
D. TEMP Set  
Right  
Left  
LOCATION AND DESCRIPTION OF CONTROLS  
C. Temperature Control/Display  
A. Main On/Off Button  
Displays the set point of the oven.  
Turns all oven functions on or off. If the oven is below the set  
point, it will rise to the set point and turn the conveyor on. If it is  
turned off and the oven is above 200° F, the blowers will remain  
on until the oven drops below 200° F.  
D. TEMP Set  
Pressing on the “TEMP” button shows individual displays and  
combined adjustments.  
B. Conveyor Time Setting  
E. Message Bar  
Adjusts and displays the conveyor bake time. Dual belt ovens  
have two displays, single units have one.  
Indicates various messages pertaining to current oven  
conditions.  
16  
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NORMAL OPERATION - STEP-BY-STEP  
2. Push the “ON/OFF” button to start the oven. The con-  
A. Main Screen  
troller will display the screen, as shown in Figure 3-3.  
1. When the unit has been “OFF” for more than 1 minute  
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.  
Figure 3-3 Main Screen ON  
Figure 3-1 Screen Saver  
FRONT BELT JAMMED  
450 F  
BELT 01 SPEED  
ON  
4m. 30s.  
TheMiddleby Corporation  
1400Toastmaster Drive  
Elgin,IL 60120  
Phone:847-741-3300  
Fax:  
847-741-0015  
©2005 Middleby Corporation,All rightsreserved  
ON/OFF button  
3. To change the temperature, push the “TEMP” button. The  
controller will display the screen, shown in  
Figure 3-4. To change the temperature, push the “”  
arrow button. Then push either the “” arrow or “” arrow  
buttons to increase or decrease temperatures respec-  
tively. When the proper temperature is entered, push the  
“Enter/Reset” button. The controller will now show the  
display shown in Figure 3-3.  
Figure 3-2 Main Screen OFF  
The Middleby Corporation  
450 F  
BELT 01 SPEED  
OFF  
4m. 30s.  
Figure 3-4 Temperature Screen  
TEMPERATURE SET UP  
ACTUAL TEMP  
133.8 F  
ON  
450.0 F  
TEMP Set button  
17  
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4. To change the conveyor belt speed, push the “TIME”  
button. The controller will display the screen, shown in  
Figure 3-5. To change the minute setting, push the “”  
arrow button. Then push either the “” arrow or “” arrow  
buttons to increase or decrease the time accordingly. To  
change the second setting, push the “” arrow button.  
Then push either the “” arrow or “” arrow buttons to  
increase or decrease the time accordingly. When the  
proper times are entered, push the “ENTER/RESET” but-  
ton. The controller will now show the display shown in  
Figure 3-3.  
C. Daily Shutdown Procedure  
1. Make certain there are no products left on the conveyor 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. After the oven has cooled and the blowers have turned off, 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.  
Figure 3-5 Belt Speed Screen  
Message Bar  
4. Energy level indicators - Indicators to either side of the  
screen indicate the energy input to that side of the oven.  
5. Message bar - Indicates various messages pertaining to  
current oven conditions.  
BELT 01 SPEED  
LEFT FOR MINUTES - RIGHT FOR SECONDS  
B. Oven Temperature/Set Point/Indicator Screen  
1. Actual temperature - Indicates current average tempera-  
ture of the right side of the oven.  
4m. 30s.  
2. Set point temperature - Pressing on this value allows the  
user to adjust the set point of the oven.  
3. Exit - Returns to the main screen.  
C. Energy Modes  
Energy Mode One - This mode is automatic, and starts (bake  
time +1 minute) after the last product has entered  
theoven. Inthismode, themainovenblowerswilllowerto1200  
RPM, while the oven maintains temperature and belt speed.  
ON/OFF button  
TEMP button  
TIME button  
B. Daily Startup Procedure  
1. Checkthatthecircuitbreaker/fuseddisconnectisintheOn  
position. Check that the window is closed. The touch panel  
display should be lit.  
2. Adjust the conveyor to the desired bake time.  
3. Press the temperature button to display the oven setting.  
Set temperature 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.  
18  
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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  
blockage.  
Startup Sensor faulty or  
sensor window dirty.  
Clean window.  
Sensor requires maintenance, call for service.  
IV. SCREEN ALERTS  
SYMPTOM  
PROBLEM  
SOLUTION  
Battery Symbol in the  
lower right hand corner  
The internal battery needs  
to be replaced to retain en-  
ergy mode timings.  
A qualified service technician should accomplish this.  
High Control Compartment  
Temperature  
Clean rear grills.  
Failure to do this will eventually shut down the oven due to  
excessive temperature.  
Control Over Temp  
Front belt jammed  
Rear Grills are clogged.  
Front belt has stopped.  
Clean grills.  
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  
Normal operation.  
19  
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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) and disconnect the electric supply to the oven.  
3. If it is necessary to move a gas oven for cleaning or servicing, disconnect the gas supply before moving 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. If the restraint cable was disconnected to clean or  
service the oven, reconnect it at this time.  
3. Reconnect the gas supply.  
5. Turn on the full-flow gas safety valve. Test the gas  
line connections for leaks using approved leak test  
substances or thick soap suds.  
6. Turn on the electric supply circuit breaker(s).  
7. Perform the normal startup procedure.  
4. Reconnect the electrical supply.  
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 or pressurized steam-cleaning equipment when cleaning this oven. To avoid saturating the oven  
insulation, DO NOT use excessive amounts of water. DO NOT use a caustic oven cleaner, which can damage the 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  
Figure 4-1. Cooling Vents and Grills  
A. Check that the oven is cool and the power is discon-  
nected, 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.  
Vents on  
front panel  
of oven  
CAUTION: If a cooling fan is not operating correctly, it must  
bereplacedIMMEDIATELY. Operatingtheoven  
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. If necessary, refer  
to Figure 2-16 (in Section 2, Installation) when replacing  
the crumb trays into the oven.  
Fan grills (2) on rear  
of oven and control  
compartment  
Vent (1) on rear  
of machinery  
compartment  
G. Clean the window in place.  
20  
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Figure 4-2. Removing Air Fingers and Plates  
II. MAINTENANCE – MONTHLY  
NOTE: When removing the conveyor, refer to Figure 2-12 (in  
Section 2, Installation).  
A. Check that the oven is cool and the power is disconnected,  
as described in the warning at the beginning of this Section.  
B. Remove the crumb trays from the oven.  
C. Lift the drive end of the conveyor slightly, and push it  
forward into the oven. This removes the tension from the  
drive chain. Then, remove the drive chain from the con-  
veyor sprocket.  
D. Slide the conveyor out of the oven, folding it as it is removed.  
NOTE: Split belt conveyors can only be removed from the end  
of the oven with the drive motor.  
Single-belt conveyor assemblies may be removed  
from either end of the oven. If it is to be removed from  
the end of the oven without drive motor, remove the  
drive motor sprocket as described in the Conveyor  
Installation instructions (in Section 2, Installation).  
Figure 4-3. Disassembling the Air Fingers  
E. Remove the end plugs from the oven. The end plugs are  
shown in Figure 1-1 (in Section 1, Description).  
F. 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  
T5 T6  
(Bottom Row) B1 B2 B3  
B4 B5 B6  
G. Disassemble the air fingers as shown in Figure 4-3. AS EACH  
FINGERISDISASSEMBLED,WRITETHE“LOCATIONCODE”  
FOR THE FINGER ON ALL THREE OF ITS PIECES. This will  
help you in correctly reassembling the air fingers.  
CAUTION: Incorrectreassemblyoftheairfingerswillchange  
the baking properties of the oven.  
H. 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.  
I. Reassemble the air fingers. Then, replace them in the  
oven, using the “location guide” as a guide.  
J. Replace the end plugs on the oven.  
K. Reassemble the conveyor into the oven. If the drive  
sprocket was removed when installing the conveyor,  
replace it at this time.  
L. Reattach the drive chain.  
M. Check the tension of the conveyor belt as shown in Figure  
2-14 (in Section 2, Installation). The belt should lift  
between 3 - 4(75-100mm). DO NOT OVERTIGHTEN  
THE CONVEYOR BELT. If necessary, the belt tension  
can be adjusted by turning the conveyor adjustment  
screws, located at the idler (right) end of the conveyor.  
N. Replace the crumb trays.  
21  
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8. Reassemble the idler shaft into the conveyor. Make  
sure that the bronze washer is in place between the  
two sections of the shaft. See Figure 4-4.  
III. MAINTENANCE – EVERY 3 MONTHS  
A. Check that the oven is cool and the power is discon-  
nected, as described in the warning at the beginning of  
this Section.  
9. Replacetheconveyoradjustmentscrewsasshownin  
Figure4-4. Toallowtheconveyorbelttobereinstalled  
later, do not tighten the screws at this time.  
B. Vacuum both of the blower mounts, and their surrounding  
compartments, using a shop vacuum.  
10. Loosen the set screw on both of the conveyor drive  
sprockets.Then,removethesprocketsfromtheshaft.  
C. Tighten all electrical terminal screws.  
D. Split Belt Disassembly and Cleaning  
11. Check the conveyor configuration as follows:  
1. Refer to Part D, Conveyor Installation, in the Installa-  
tionsectionofthisManual.Then,removethefollowing  
components from the oven:  
High-speed conveyors are equipped with large flange  
bearings at both ends of the shaft, as shown in  
Figure 4-5. For these conveyors, remove the two  
screws that hold each bearing to the conveyor frame.  
Withthescrewsremoved,lifttheendoftheshaftatthe  
front of the oven, and pull the entire assembly free of  
the conveyor frame.  
• Conveyor end stop  
• Crumb trays  
• Chain cover  
Standard conveyors are equipped with bronze bush-  
ings mounted on spacers at both ends of the shaft, as  
shown in Figure 4-5. For these convey-ors, remove  
the two screws that hold the bracket to the conveyor  
frame. With the screws removed, lift the end of the  
shaft at the front of the oven, and pull the entire  
assembly free of the conveyor frame. The brackets  
will be removed along with the drive shaft assembly.  
• Drive chains  
• End plugs  
• Conveyor assembly  
2. Remove the master links from each conveyor belt.  
Then, rollthebeltsupalongthelengthoftheconveyor  
to remove them from the frame.  
3. Remove the two conveyor adjustment screws from  
the idler end of the conveyor frame, as shown in  
Figure 4-4.  
12. Disassemble and lubricate the two sections of the  
drive shaft as described for the idler shaft, above.  
13. Before reassembling the shafts into the conveyor  
frame, check that they are oriented properly.  
4. Remove the idler shaft assembly from the conveyor.  
5. Pull apart the two sections of the idler shaft.  
14. Reassemble the drive shaft into the conveyor. Make  
sure that the bronze washer is in place between the  
two sections of the shaft. See Figure 4-4.  
6. Cleantheshaftsthoroughlyusingarag.Then,lubri-cate  
both the extended shaft and the interior of the hollow  
shaft using a light food-grade lubricant. DO NOT  
lubricate the shafts using WD40 or a similar product.  
This can cause the shafts to wear rapidly.  
15. Replace the drive sprockets. Reassemble the belts  
and master links onto the conveyor.  
16. Reinstall the end plugs and conveyor onto the oven.  
17. Reattach the drive chains. Replace the chain cover.  
7. Before reassembling the shafts into the conveyor  
frame, check that they are oriented properly.  
18. Check the tension of the conveyor belt as shown in  
Figure2-14(inSection2,Installation).Thebeltshould  
lift about 1(25mm). If necessary, adjust the belt  
tension by turning the conveyor adjustment screws.  
Figure 4-4. Disassembling the idler shaft  
19. Replace all components onto the oven.  
Figure 4-5. Drive shaft configurations  
22  
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Figure 4-7. Rear panel access  
Figure 4-6. Disassembling the drive shaft  
Remove eight (8)  
screws to remove  
rear panel  
Bearings  
(2 total)  
Grease fitting  
(1 per  
bearing)  
Blower belt  
Blower motor  
Loosen four (4) screws to adjust  
motor position and belt tension  
E. Blower Belt  
IV. MAINTENANCE - EVERY 6 MONTHS  
1. Remove the six screws shown in Figure 4-7. Then,  
remove the rear panel from the oven.  
A. Check that the oven is cool and the power is discon-  
nected, as described in the warning at the beginning of  
this Section.  
2. Check the blower belt for the proper 1/4(6mm) deflec-  
tion at the center, and for cracking or excessive wear.  
B. Check for excessive wear on the conveyor drive motor  
brushes. The brushes should be replaced if they have  
worn to less than 1/4(6mm) in length. Be sure to replace  
the brushes in exactly the same position.  
See Figure 4-7. Overtightening the belt will cause premature  
bearing failure and possible vibrations. A loose belt may also  
cause vibrations.  
3. If necessary, adjust the tension of the belt by loosening  
the four motor mounting bolts. Reposition the motor as  
neccessary until the correct 1/4(6mm) deflection is  
reached, then tighten the bolts.  
C. For gas ovens, inspect and clean the burner nozzle and  
the spark electrode assembly.  
D. Check the conveyor drive shaft bushings and spacers.  
Replace the components if they are worn.  
23  
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V. KEY SPARE PARTS – Available separately. See Figure 4-8.  
1
2
3
4
5
10  
16, 17, 18  
22  
23  
19  
20  
21  
Figure 4-8. Key Spare Parts  
KEY SPARE PARTS PS640 GAS (B & W Touchscreen)  
ITEM QTY.  
P/N  
DESCRIPTION  
1
2
1
1
1
1
1
1
1
1
1
60191  
58920  
58679  
60192  
M9608  
60196  
97525  
51399  
50610  
57288  
50239  
60679  
60671  
33983  
32108  
60193  
58668  
58669  
60091  
59132  
59668  
48455  
50240  
Digital Display, Programmed  
Motor, Conveyor Drive  
Conveyor Control Board  
Inverter, Programmed  
Power Supply  
3
4
5
6
Kit, Thermocouple  
7
Fan Cooling Control  
Fan Cooling Rear  
8
9
Air Switch  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
1
Motor, Blower  
1
1
1
1
2
1
1
1
1
2
1
1
1
Ignition Module  
Assy, Valve Gas Modulating  
Board, Signal Cond. 0-15VDC  
High Limit Control Module,240V  
Transformer,240Vp:24Vs  
PLC ModuIe, Programmed  
Thermocouple Module  
Current Module  
PhotoCell  
Relay, DPDT 24V Coil  
Belt, Blower  
Ignitor, Single Rod  
Ignition Cable, 25  
24  
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SECTION 5 - WIRING DIAGRAM  
25  
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NOTES  
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NOTES  
27  
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WARNING  
Improper installation, adjustment, alteration, service or maintenance  
can cause property damage, injury or death. Read the installation,  
operating and maintenance instructions thoroughly before  
installing or servicing this equipment.  
NOTICE  
During the warranty period, ALL parts replacement and servicing should be performed  
by your Middleby Marshall Authorized Service Agent. Service that is performed by  
parties other than your Middleby Marshall Authorized Service Agent may void your  
warranty.  
NOTICE  
Using any parts other than genuine Middleby Marshall factory manufactured parts  
relieves the manufacturer of all warranty and liability.  
NOTICE  
Middleby Marshall reserves the right to change specifications at any time.  
Middleby is proud to support the Commercial Food Equipment  
Service Association (CFESA). We recognize and applaud  
CFESA's ongoing efforts to improve the quality of technical  
service in the industry.  
Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • USA • (847)741-3300 • FAX (847)741-4406  
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