Middleby Marshall Oven PS540 User Manual

PS540-Series Gas Ovens: English

Middleby

Marshall

AMIDDLEBYCOMPANY

owner's

operating

& installation

manual

PS540-Series OVENS

Model PS540G

PS540 (Single)

PS540 (Triple)

PS540 (Double)

Part No. 50664

Price $30.00

P: 10/06

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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 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.

Thiswarrantyisnotvalidunlessequipmentisinstalled,started,

and demonstrated under the supervision of a factory-autho-

rized installer.

Normal maintenance functions, including lubrication, adjustment of

airflow, thermostats, door mechanisms, microswitches, burners

and pilot burners, and replacement of light bulbs, fuses and indicat-

ing 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.

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

iii

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TABLEOFCONTENTS

(Continued)

Page

SECTION 1

Daily Startup................................................................. 26

Power Failure ............................................................... 26

B. Shutdown Procedure............................................... 26

A.Daily Startup Procedure .......................................... 28

IV. NORMAL OPERATION - STEP-BY-STEP .................. 28

V. QUICK REFERENCE: TROUBLESHOOTING ............. 30

I. MODELIDENTIFICATION .............................................. 1

SERIES PS540 ELECTRICAL SPECIFICATIONS............. 2

II. PRINCIPLE OF AIR FLOW............................................. 3

A. Heat Transfer and How It Works .............................. 3

II. PRINCIPLE OF AIR FLOW (Continued) ........................ 4

B. Air Fingers ................................................................. 4

III. COMPONENT FUNCTION ............................................ 5

A. Conveyor Motor and Conveyor Belt ........................ 6

B. Blower Fan ................................................................. 6

C. Gas Burner ................................................................ 6

D.Window ....................................................................... 6

E.CoolingFan ................................................................ 7

F. Air Fingers and Blank Plates - See Figure 1-9......... 8

SECTION 2

I. UNLOADING ................................................................... 9

PS540 OVEN INSTALLATION

REQUIRED KITS AND EQUIPMENT ........................ 10

PARTS LIST FOR SERIES PS540 GAS OVEN

INSTALLATION KIT P/N 50633 ................................ 10

PARTS LIST FOR PS540 SERIES SINGLE OVEN

OPTION - BASE W/15″ LEGS & TOP P/N 34832 ..... 11

PARTS LIST FOR PS540 SERIES DOUBLE OVEN

OPTION - BASE W/6″ LEGS,

CASTERS & TOP P/N 34833 .................................... 12

PARTS LIST FOR PS540 SERIES TRIPLE OVEN

OPTION - BASE w/OUTRIGGERS & TOP

P/N 34831................................................................... 13

RESTRAINT CABLE INSTALLATION.......................... 16

UTILITY ROUGH-IN DIMENSIONS AND POSITIONING

FOR PS540-SERIES OVENS .................................... 17

ELECTRICAL SAFETY SWITCH .................................. 17

ELECTRICAL SPECIFICATIONS ................................. 17

GAS RATING ................................................................ 17

MINIMUM GAS METER RATING.................................. 17

MINIMUM GAS PIPE SIZE ............................................ 17

GAS SAFETY VALVE ................................................... 17

REQUIRED GAS SUPPLY PRESSURE....................... 17

SUGGESTED ................................................................ 17

User supplied Items..................................................... 17

II. VENTILATIONGUIDELINES ....................................... 18

VENTILATIONHOOD ................................................... 18

VENTILATION CAPTURE TEST................................... 18

III. ELECTRICAL CONNECTION INFORMATION FOR

PS540-SERIES OVENS. ........................................... 19

IV. ELECTRIC SUPPLY FOR GAS-HEATED OVENS ..... 19

V. GAS SUPPLY FOR GAS HEATED OVENS................. 20

VI. CONVEYOR REAR STOP AND

SECTION 4 MAINTENANCE

I. MAINTENANCE - DAILY ........................................... 32

A. Exterior .................................................................... 32

B. Cooling Fan .............................................................. 32

C. Conveyor Belt ......................................................... 32

D. Crumb Pans ............................................................ 32

E. Window .................................................................... 32

II. MAINTENANCE - MONTHLY ...................................... 33

A. Removing Conveyor From Oven For Cleaning .... 33

B. Air Fingers Disassembly For Cleaning................. 35

C. CleaningtheWindow .............................................. 36

D. Reassembly of Air Fingers .................................... 36

E. Reinstall End Plugs................................................. 39

F. Conveyor Reassembly Into Oven.......................... 40

G. Checking Conveyor Belt Tension ......................... 40

H. Conveyor Belt Link Removal ................................ 41

I. Replacing Conveyor Belt......................................... 42

J. Attaching Drive Chain ............................................ 42

III. MAINTENANCE - EVERY 3 MONTHS ........................ 43

A. Cleaning the Blower/Fan Motor ............................. 43

B. Electrical Terminals ............................................... 44

C. Ventilation ............................................................... 44

D. Checking the Blower/Fan Belt ............................... 44

E. Blower Fan Shaft Bearing Lubrication .................. 45

F. Split-belt Conveyor Shaft Cleaning ........................ 45

IV. MAINTENANCE - EVERY 6 MONTHS .................... 47

PS540-SERIES GAS OVEN KEY SPARE PARTS KIT,

p/n 36805 ................................................................... 48

KEY SPARE PARTS KIT .............................................. 48

SECTION 5 TROUBLESHOOTING

TroubleshootingCharts ..................................................... 49

SECTION 6 - PARTS LIST

OVEN PANELS, WINDOW AND LEGS ............................ 53

CONTROL PANEL ........................................................... 55

BLOWER AND SHROUD ................................................. 57

CONVEYOR ...................................................................... 59

SPLIT BELT CONVEYOR ................................................. 61

GAS BURNER AND PIPING ASSEMBLY ....................... 63

MACHINERY COMPARTMENT ....................................... 65

SECTION 7 ELECTRICAL SCHEMATICS

Wiring Diagram, G208-240 50/60, 1PH 3W PS540 ........ 67

END STOP INSTALLATION ...................................... 21

SECTION 3 INSTALLATION

I. CONTROL FUNCTIONS ................................................ 23

II. COMPONENT INFORMATION AND LOCATION ......... 24

A. Door Safety Switch.................................................. 24

B. Blower Switch .......................................................... 24

C. Heat Switch .............................................................. 24

D. Temperature Controller .......................................... 24

E. Conveyor ................................................................. 25

MEASURING CONVEYOR SPEED. ............................. 25

III. STEP-BY-STEPOPERATION ..................................... 26

A. Startup Procedures................................................. 26

NOTE

Wiring Diagrams are in Section 7 of this Manual.

The diagram for each oven is also on the lower

inner surface of its Control Console.

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SECTION 1

DESCRIPTION

SECTION 1

DESCRIPTION

I. MODEL IDENTIFICATION

TheMiddlebyMarshallPS540-Seriesmaybeusedeither

as a single oven or stacked for use as double or triple

ovens. Themajordifferencebetweentheovenmodelsin

this series is the width of the conveyor.

A single PS540-Series Oven (Figure 1-1) is mounted on a

basepadwithlegsandcasters.Adoubleoven(Figure1-2)

consists of two, stacked, single ovens. A triple oven

(Figure 1-3) consists of three stacked single ovens. The

lower oven is mounted on a base pad with short legs and

casters.

On a double or triple oven, the ovens operate completely

independent. Allovensuseidenticalcontrolsandcompo-

nents. One oven can be cleaned or serviced, while the

othersareoperating.

Figure 1-1. Single PS540 Oven

Figure 1-2. Double PS540 Oven

Figure 1-3. Triple PS540 Oven

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SECTION 1

DESCRIPTION

PS540 SERIES OVEN SPECIFICATIONS

Conveyor Belt Width

Heating Zone Length

Baking Area Square Feet

32″ (813mm)

40-1/2″ (1028mm)

9 sq. ft. (0.84 sq. m.)

Overall Dimension

Standard Single Oven w/Legs

80″ (2032mm) L ×

61-5/16″ (1557mm) W ×

47-5/16″ (1202mm) H ×

Overall Dimension

Double Oven

80″ (2032mm) L ×

61-5/16″ (1557mm) W ×

60-15/16″ (1548mm) H x

Overall Dimension

Triple Oven

80″ (2032mm) L x

61-5/16″ (1557mm) W ×

77-1/2″ (1969mm) H ×

Weight of Single Oven

Shipping Weight

Shipping Cube

925 lb (419kg)

1,100 lb (498.3kg)

Approx. 132 ft³(3.74 m³)

Operating Range

110,000 BTU/hr

(116.0 mJ/h)

(27,720 kcal)

(32.2 kW/hr)

Maximum Operating Temperature

Warm-up Time

550°F (287°C)

10 min.

Gas Oven Inlet Line Size

Minimum Gas Meter Rating

3/4″ (19mm) ID for each oven

450 cu.ft./hr. (12.74m³h) for 1 to 2 ovens

Add 180 cu.ft./hr (5.1m³h) for each additional oven

Minimum Gas Pipe Size

Natural (must be dedicated line)

Propane (must be dedicated line)

2″ (51mm) ID for 1, 2, or 3 ovens

Gas Pressure

Natural

Propane

Inlet

1.13 kPa

2.75 kPa

Test Power

0.87 kPa

2.39 kPa

6″ to 12″ Water Column (13.8 to 29.9 mbar)

11.5″ to 12″ Water Column (28.7 to 29.9 mbar)

Gas Valve

0.75″ (19mm) ID full-flow, gas, shutoff valve installed in oven inlet gas line.

A separate connection and valve must be provided for each oven.

Recirculating Air Fan

Air Velocity

One fan at 2300 RPM

3000 fpm (1524 cm/sec) (Average)

Bake Time

3 min. 0 sec. Bake Time minimum

30 min. 0 sec. Bake Time maximum

SERIES PS540 ELECTRICAL SPECIFICATIONS

Main Blower &

Elements Voltage

Control Circuit

Voltage

Phase

Frequency

Amperage

Draw

Poles

Wires

208-240V

1 Ph

50/60 Hz

4.1 Amp

3 Pole

3 Wire

(2 hot, 1 grd)

NOTE

Wiring Diagrams are contained in Section 7 of this Manual

and are also located inside the oven at the

bottom of the Control Panel

This Manual Must Be Kept For Future Reference

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SECTION 1

DESCRIPTION

II. PRINCIPLE OF AIR FLOW

Thefan-styleblowerdrawsairintotheovenplenumwhere

itisheated.Theblowerthenpushesthehotairthroughthe

air fingers into the baking chamber. Each air finger

containsaninnerplateandouterplatethatformthehotair

intojets,distributingitacrossaconveyorbeltonwhichthe

food product rides. Air is then pulled back into the blower

and the process continues. The curving, black arrows of

Figure 1-4 show this air flow.

PS540-Series Oven is light in color: To reflect more heat

back onto the food product.

Convection: Thispathhastodowithmovingavolumeof

air.Itexplainswhyhotairrisesandcoolerairreplaceshot

air. An industrial application of this principle is to incorpo-

rate a fan to force the hot air movement, which in turn

increases the heat transfer to the food product.

Each PS540-Series Oven has a large fan-style blower to

move the hot air through the air fingers and onto the

product to cook/bake the food product most efficiently.

A. Heat Transfer and How It Works

1. Heat constantly moves from a warm object to a cold

object. Heat moves using three different paths: Conduc-

tion; Radiation; and Convection.

2. Temperature is the intensity of heat at the point where

it is sensed. As discussed above, heat flows by conduc-

tion,radiationandconvection.Thespeedatwhichtheheat

flowsisdeterminedbythetemperaturedifferencebetween

the oven and the food product. The larger the difference,

the faster the heat flows to the item that is being baked.

Conduction: This path utilizes surface-to-surface con-

tact. The pizza dough in contact with the pan is a good

example of conduction.

Radiation: Thispathhastodowithobjectsradiatingheat.

Dark objects absorb heat whereas light or shiny objects

reflect more heat. This is the reason that the inside of a

Conveyor Belt(s)

Window

Upper Air Fingers

Lower Air Fingers

Figure 1-4. PS540-Series Oven Air Flow

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SECTION 1

DESCRIPTION

II. PRINCIPLE OF AIR FLOW (Continued)

B. Air Fingers

Seriesovensusedtobakepizzahavefourbottomfingers

and two top fingers. For special product baking require-

ments, a number of other styles of fingers and finger

arrangements are available from the factory.

The PS540-Series Ovens are conveyorized ovens that

employ vertical jets of hot air streaming from air fingers

(Figure 1-5) to give uniform, intense heating. The vertical

streamsofhotairprovideanexceptionalheattransferrate

andgenerallybakefasterandatlowertemperaturesthan

convection hot air or infrared heating ovens.

NOTE: Some customers have a predetermined finger

arrangement. If you have any questions pertaining to the

finger arrangement, please call the factory.

A PS540-Series Oven can accommodate up to four

bottom air fingers and four top air fingers. Some PS540-

Manifold

Air Flow

From Plenum

Manifold Baffle

Outer Plate

Inner Plate

High Velocity

Columns of Air

on Food Product

Air Flow

From Plenum

Manifold Baffle

Inner Plate

Outer Plate

Manifold

Figure 1-5. Air Fingers, Showing High-Velocity Columns of Air Formed During Passage Through

the Inner Plate and Outer Plate to Heat the Food Product.

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SECTION 1

DESCRIPTION

III. COMPONENT FUNCTION (Figure 1-6)

Figure 1-6. PS540-Series Oven Components Locations

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SECTION 1

DESCRIPTION

III. COMPONENT FUNCTION

A. Conveyor Motor and Conveyor Belt

The conveyor belt is driven by a variable-speed electric

motor(Figure1-7)operatingthroughagearreducer. The

motor speed is controlled by a digital control. The stain-

less-steelwirebeltcantravelineitherdirectionatvariable

ratesrangingfrom3minutesto30minutes;thisisthetime

that a product can take to pass through the oven.

B. Blower Fan

The blower fan is located at the rear of the oven. This

blower forces heated air through the air fingers. The

BLOWER switch must be set to “ON” or “I” for oven

warmupandbaking.

C. Gas Burner

Turning the HEAT switch to “1” activates the oven purge

circuit. After approximately 30 seconds, the solid-state

ignition control lights a pilot burner by an electric spark.

Thissystempermitsthemaingasvalvetoopenonlyafter

the lighting of the pilot burner is detected by the flame

sensor.

Left Control Box

If the pilot flame does not light or a loss of flame occurs,

the main gas valve closes.

The main burner gas is extinguished when the HEAT

switch is set to “OFF” or “O”.

D. Window

Awindowonthefrontoftheovenpermitsviewingtheitems

beingbakedandprovidesaccesstotheovenforitemsthat

do not require full baking time, such as sandwiches,

cookies, small items, or cheese-melting processes.

Right Control Box

Figure 1-7. Machinery Compartment

Components

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SECTION 1

DESCRIPTION

E. Cooling Fan — See Figure 1-8

The cooling fans are located in the back of the oven.

These cooling fans draw air through its grille, blowing it

through the blower motor compartment and the control

compartmentintotheoventopandexhaustedoutthefront

louvers.

CoolingFanGrille

Figure 1-8. Cooling Fan

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SECTION 1

DESCRIPTION

F. Air Fingers and Blank Plates - See Figure 1-9

F1. Air Fingers

F2. Blank Plates

1. Blank Plates- The Blank Plates are available to install

on the plenum where an air finger is not required.

An Air Finger Assembly is made up of three parts:

1.OuterPlate-TheOuterPlateistheremovablecovering

with tapered holes, which direct the air stream onto the

productbeingbaked.

2.InnerPlate-TheperforatedInnerPlateisvitalinforming

theuniqueairjets.Itmustbeassembledintothemanifold

with its holes aligned with the holes of the outer plate.

3. Manifold - The Manifold is the assembly which slides

on tracks into the oven plenum.

Half Blank Plate

Outer Plate

Inner Plate

Blank Plate

Finger

Manifold

Assembly

Baffle

Figure 1-9. Blank Plates (two sizes) and an Air Finger.

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SECTION 2

INSTALLATION

SECTION 2

INSTALLATION

NOTE: InU.S.A.,theoveninstallationmustconformwith

I. UNLOADING

local codes, or in the absence of local codes, with the

NationalFuelGasCode, ANSI Z223.1latestedition. The

oven, when installed, must be electrically grounded in

accordance with local codes, or in the absence of local

codes, with the National Electrical Code (NEC), or

ANSI/NFPA70.

Your Middleby Marshall PS540-Series Oven is shipped

partially assembled. It will arrive in a carton on a crate.

Carton size for a PS540-Series Oven is:

84″ (2134mm)Long×

58″ (1473mm) Wide ×

NOTE: InCanada,theoveninstallationmustconformwith

local codes, or in the absence of local codes, with the

Natural Gas Installation Code, CAN/CGA-B149.1, or the

Propane Gas Installation Code, CAN/CGA-B149.2, as

applicable. Theoven, wheninstalled, mustbeelectrically

grounded in accordance with local codes, or in the ab-

sence of local codes, with the Canadian Electrical Code

CSA, C22.2, as applicable.

44″ (1118mm) High ×

Thecrateandcartonmustbeexaminedbeforesigningthe

Bill of Lading. Report any visible damage to the transport

company, and check for the proper number of crates. If

apparent damage is found, make arrangements to file a

claim against the carrier. Surface Interstate Commerce

Regulations (U.S.A.) require that the claim must be

initiatedbytheconsigneewithin10daysfromthedatethat

the shipment is received.

NOTE: For Australian installation, the oven must be

installedonlybyanauthorisedpersoninaccordancewith

AS5601, local authority, gas, electricity, any applicable

statutoryregulationsandmanufacturerrequirements.

APre-installationProceduresManual(MMP/N88910-0009)

is attached to the exterior wall of the carton. This manual

containsdetailedinstructionsonunpackingandmovingthe

oven(s) to the operating site. When the transport company

notifiesyouofanimpendingdelivery,arrangetohaveaforklift

at your facility to unload the carton(s).

NOTE

There must be adequate clearance between

the oven and any adjacent combustible con-

struction. Clearance must also be provided

for servicing and for operation.

Instructions for stacking the ovens is continued in a

separate manual used by Middleby Marshall Authorized

Installers.

If you have a door wider than the carton, simply move the

carton into your facility and arrange an appointment with

your Middleby Marshall Authorized Installer.

CAUTION

It is required that the oven be placed under a

ventilation hood for adequate air supply and

ventilation.

If your door is narrower than the carton, then the oven will

have to be unpacked. Follow the directions shown in the

Pre-InstallationProceduresManual.

CAUTION

Do not obstruct the flow of combustion and

ventilation air to and from your oven. Do not

obstructtheventilationholesintheControlPanel.

CAUTION

On ovens with the Machinery Drive Compartment

locatedattherightend,aminimumclearanceof0″

toaleftsidewall,18″toarightsidewalland6″from

a back wall to air openings at the rear of the oven

mustbemaintained.Onovenswiththemachinery/

drive compartment located at the left end, a mini-

mumclearanceof0″toarightsidewall,18″toaleft

side wall and 6″ from a back wall to air openings at

the rear of the oven must be maintained.

For servicing and cleaning, a minimum of 18″

clearance from all walls is recommended.

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SECTION 2

INSTALLATION

PS540 OVEN INSTALLATION

REQUIRED KITS AND EQUIPMENT

TYPE

INSTALLATION

PS540

Gas Oven

Installation

Kit P/N

PS540 Single

Oven Option

Base w/15″ Legs,

Casters & Top

Kit P/N

PS540 Double

OvenOption

Base w/6″ Legs,

Casters & Top

Kit P/N

PS540 Double

OvenOption

PS540 Triple

OvenOption

Base w/Casters Base w/Casters

& Top

Kit P/N

& Top

Kit P/N

50663

34832

34833

34831

51139

PS540 Single Gas Oven

PS540 Double Gas Oven

PS540 Triple Gas Oven

PARTS LIST FOR SERIES PS540 GAS OVEN

INSTALLATION KIT

P/N 50633

(Two required for double oven)

(Three required for triple oven)

ITEM

NO.

QTY

PART NO.

22361-0001

35000-1103

35900-0148

50664

DESCRIPTION

FLEXIBLE GAS HOSE

CONVEYOR END STOP

CONVEYOR LEFT REAR STOP

SERIES PS540 OWNER/OPERATOR MANUAL

SERVICE AGENCY DIRECTORY

CONVEYOR WIRE BELT

1002040

33900-0032

Figure 2-1. PS540-Series Gas Oven

Installation Parts

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SECTION 2

INSTALLATION

Figure 2-2. Model PS540 Single Oven

Option Base with Legs and Top

PARTS LIST FOR PS540 SERIES SINGLE OVEN OPTION - BASE w/15″ LEGS & TOP

P/N34832

ITEM

NO.

QTY

PART NO.

37900-0025

37900-0024

22290-0009

22290-0010

220373

21416-0001

21422-0001

21256-0008

22450-0228

33486

DESCRIPTION

COMPLETE BASE WELDMENT

TOP PLATE, LEG WELDMENT

SWIVEL CASTER W/BRAKE FLAT PLATE

SWIVEL CASTER FLAT PLATE

3/8″-16 × 1″ HEX SCREW,SST

3/8″ FLAT WASHER, SS

3/8″ SPLIT LOCK WASHER, ZP

SCREWS FOR TOP 10-32 × 3/8″ 18-8, SL TRUS S

RESTRAINT CABLE ASSEMBLY

TOP COVER 304 PANEL

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SECTION 2

INSTALLATION

Figure 2-3. Model PS540 Double Oven

Option Base with Legs and Top

PARTS LIST FOR PS540 SERIES DOUBLE OVEN OPTION - BASE w/6″ LEGS, CASTERS & TOP

P/N34833

ITEM

NO.

QTY

PART NO.

37900-0025

37900-0102

22290-0009

22290-0010

220373

21416-0001

21422-0001

21256-0008

22450-0228

33486

DESCRIPTION

COMPLETE BASE WELDMENT

TOP PLATE, LEG WELDMENT

SWIVEL CASTER W/BRAKE FLAT PLATE

SWIVEL CASTER FLAT PLATE

3/8″-16 × 1″ HEX SCREW,SST

3/8″ FLAT WASHER, SS

3/8″ SPLIT LOCK WASHER, ZP

SCREWS FOR TOP 10-32 × 3/8″ 18-8, SL TRUS S

RESTRAINT CABLE ASSEMBLY

TOP COVER 304 PANEL

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SECTION 2

INSTALLATION

Figure 2-4. Model PS540 Triple Oven

Option Base with Outriggers and Top

PARTS LIST FOR PS540 SERIES TRIPLE OVEN OPTION - BASE w/CASTERS & TOP

P/N51139

ITEM

NO.

QTY

PART NO.

54606

45209

22290-0009

22290-0010

45206

DESCRIPTION

COMPLETE BASE WELDMENT

QUAD OUTRIGGER WELDMENT

SWIVEL CASTER, W/BRAKE FLAT PLATE

SWIVEL CASTER, FLAT PLATE

INSERT,QUAD ADJUSTMENT FOOT

SPACER,QUAD CASTER

45205

220373

3/8″-16 × 1″ HEX BOLT, SST

3/8″ FLAT WASHER, SS

3/8″ SPLIT LOCK WASHER, ZP

3/8″-16 NYLON INSULATED LOCKNUT, ZC

1/2″-13 × 1-1/4″ 18-8 HEX CAPSCREW

1/2″ 18-8 FLAT WASHER

21416-0001

21422-0001

21172-0004

21216-0018

21416-0003

21426-0004

21256-0008

22450-0228

33486

1/2″ 18-8 LOCK WASHER

SCREWS FOR TOP 10-32 × 3/8″ 18-8, SL TRUS S

RESTRAINT CABLE ASSEMBLY

TOP COVER 304 PANEL

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SECTION 2

INSTALLATION

Figure 2-5. MODEL PS540 SINGLE OVEN DIMENSIONS

GAS INLET

ELECTRICALJUNCTIONBOX

RECOMMENDEDMINIMUMCLEARANCES:

Rear of Oven to Wall - 6″ (150mm)

Non-control End of Oven to Wall - 0″

Control End of Oven to Wall - 0″

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SECTION 2

INSTALLATION

Figure 2-6. MODEL PS540 DOUBLE OVEN DIMENSIONS

GAS INLET

ELECTRICALJUNCTIONBOX

RECOMMENDEDMINIMUMCLEARANCES:

Rear of Oven to Wall - 6″ (150mm)

Non-control End of Oven to Wall - 0″

Control End of Oven to Wall - 0″

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SECTION 2

INSTALLATION

Figure 2-7. MODEL TRIPLE OVEN DIMENSIONS

GAS INLET

ELECTRICALJUNCTIONBOX

RECOMMENDEDMINIMUMCLEARANCES:

Rear of Oven to Wall - 6″ (150mm)

Non-control End of Oven to Wall - 0″

Control End of Oven to Wall - 0″

RESTRAINT CABLE INSTALLATION

Installtherestraintcableassemblyontheoven,asshown

in Figure 2-6.

Figure 2-8. Restraint Cable Assembly Installation

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SECTION 2

INSTALLATION

UTILITY ROUGH-IN DIMENSIONS AND POSITIONING

FOR PS540-SERIES OVENS

WARNING

DO NOT USE CONDUIT OR GAS LINE

FOR GROUND CONNECTION.

24"

610mm

CAUTION

IT IS REQUIRED THAT THE OVEN BE

PLACED UNDER A VENTILATION

HOOD FOR ADEQUATE AIR SUPPLY

AND VENTILATION.

27"

686mm

24"

610mm

13-1/2"

343mm

ELECTRIC AND GAS SUPPLY TO BE

PROVIDEDBYCUSTOMER

Suggested dimensions are shown; utility code

requirements supersede any factors shown.

ELECTRICALSAFETYSWITCH

15 Amp circuit breaker / fused disconnect switch with

lockout/tagout electrical shutoff for each oven. Wire

each oven separately.

Figure 2-9. Typical PS540-Series Oven(s)

Installation

GAS SAFETY VALVE

ELECTRICALSPECIFICATIONS

A 3/4″ (19mm) ID (inner diameter) full-flow, gas shutoff

valve. Aseparateconnectionandvalvemustbeprovided

for each oven, as shown in Figure 2-9.

DOMESTIC or EXPORT: 208-240V blower motor,

1 phase, 4.1 Amp draw, 50/60 Hz, 208-240V control

circuit, 2 poles, 3-wire system per oven (2 hot, 1 grd).

Do NOT use conduit for ground.

REQUIRED GAS SUPPLY PRESSURE

GASRATING

Natural: 6″ to 12″ water column (13.8 to 29.9 mbar)

Propane: 11.5″ to 12″ water column (28.7 to 29.9 mbar)

ModelPS540is110,000BTU/hour, 116.0mJ/h (27,720kcal),

32.2kW/hr.

MINIMUM GAS METER RATING

SUGGESTED

450 ft³/hour (12.6m³/h) for 1 or 2 ovens;

Add 180 cu. ft./hr (5.1 m³/h) for each additional oven.

If space permits, electric and gas service should be

locatednearthecontrolconsoleendoftheoven(s)toallow

convenient access to safety switches and valves.

Minimum rating does not take other gas appliances into

consideration. Gasconsumptionvariesateachsite.Total

BTU/hr (kcal/hr) must be calculated during high flame

operation for each appliance to determine if the meter

needs to be larger.

USER SUPPLIED ITEMS (Figure 2-9)

ITEM DESCRIPTION

2″ (51mm) × 2″ (51mm) × 3/4″ (19mm) TEE

3/4″ (19mm) × 3″ (76mm) NIPPLE

3/4″ (19mm) FULL FLOW GAS SHUTOFF VALVE

2″ (51mm) × 3/4″ (19mm) 90° REDUCER ELBOW

2″ (51mm)IDGASSUPPLYPIPELINE-NATURALGAS

15 AMP TOGGLE SWITCH - 2 POLE for GAS

MINIMUM GAS PIPE SIZE

Natural: 2″ (51mm) ID for 1, 2, or 3 ovens with runs up

to 200 ft. (61m).

Must be a dedicated line.

Runs over 200 ft, (61m) consult factory.

Propane: 2″ (51mm) ID for 1, 2, or 3 ovens with runs up

to 200 ft. (61m).

Must be a dedicated line.

Runs over 200 ft, (61m) consult factory.

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SECTION 2

INSTALLATION

II. VENTILATION GUIDELINES

VENTILATION HOOD

A mechanically driven ventilation system is required for

the PS540 Series Middleby Marshall conveyorized gas

ovens. The minimum hood canopy dimensions are out-

linedbelow.

The rate of air flow exhausted through the ventilation

system is generally between 1400 and 2500 cu. ft./min.

(40 and 70 m³/min), but may vary depending on the oven

configuration and hood design. To avoid a negative

pressure condition in the kitchen area, return air must be

brought back to replenish the air that was exhausted. A

negative pressure in the kitchen can cause heat related

problems to the oven components as if there were no

ventilation at all. The best method of supplying return air

is through the heating, ventilation and air conditioning

system. Throughtheysystem,theaircanbetemperature

controlled for summer and winter. Return air can be

broughtindirectlyfromoutsidethebuilding,butdetrimen-

talaffectscanresultfromeitherextremeseasonalhotand

cold temperature from the outdoors.

Local codes and conditions vary greatly from one area to

another and must be complied with. Following are the

suggested requirements for good ventilation. Please re-

member these are recommendations or guidelines, you

may have a special condition or problem that will require

theservicesofaventilationengineerorspecialist. Proper

ventilation is the oven owner’s responsibility. Improper

ventilation can inhibit oven performance. It is recom-

mendedthattheventilationandductworkbecheckedout

everythreemonths. Greasefiltersintheintakeofthehood

may be required by local codes.

NOTE: Returnairfromfandrivensystemwithinthehood

must not blow at opening of bake chamber or poor oven

baking performance will result.

2″ (51mm)

minimum.

To allow

stacking of

ovens.

21-1/2″

(546mm)

minimum

18″

(458mm)

minimum

8″ (203mm)

minimum

1″ (25mm)

minimum

Figure 2-10. Vent Hood

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SECTION 2

INSTALLATION

(U.S.A.); the Canadian Electrical Code, CSA C22.2; the

Australian Code AG601; or other applicable regulations.

III. ELECTRICAL CONNECTION

INFORMATION FOR PS540-SERIES

OVENS.

The supply conductors must be of the size (#14 AWG,

copper) recommended. (Refer to the wiring diagrams of

Section 7.) All gas oven electric supply connections are

madeviatheelectricaljunctionboxontherearoftheoven

(Figure 2-12). The power lines then connect through an

oven safety switch (on the control console door frame) to

the oven circuits. Opening the door interrupts electric

power to the oven.

WARNING

Authorized supplier personnel normally accom-

plish the connections for the ventilation system,

electric supply, and gas supply, as arranged by

the customer. Following these connections, the

factory-authorizedinstallercanperformtheinitial

startup of the oven.

CAUTION

Before connecting incoming power to the oven,

measure the voltage of each input leg to

neutral. The expected voltage is approximately

120 volts. Any voltage reading exceeding 130

volts indicates that the supply has a ‘high’ leg.

CONNECTING A ‘HIGH’ LEG TO THE OVEN

VOIDS ALL OVEN WARRANTIES. Connecting

a ‘high’ leg to the black lead of the oven can

severely damage the oven’s electrical and

electroniccomponents.

Checktheovendataplate(Figure2-11)beforemakingany

electric supply connections. Electric supply connections

must agree with data on the oven data plate.

NOTE: The electric supply installation must satisfy the

requirements of the appropriate statutory authority, such

as the National Electrical Code (NEC), ANSI/NFPA70,

(U.S.A.); the Canadian Electrical Code, CSA C22.2; the

Australian Code AG601; or other applicable regulations.

A fused disconnect switch or a main circuit breaker

(customer furnished) MUST be installed in the electric

supply line for each oven; it is recommended that this

switch/circuitbreakerhavelockout/tagoutcapability.The

electricsupplyconnectionmustmeetallnationalandlocal

electricalcoderequirements.Copperistherecommended

material for the electrical supply conductors.

CAUTION

DO NOT CONNECT BLACK

WIRE TO HIGH LEG.

IV. ELECTRIC SUPPLY FOR GAS-

HEATED OVENS

VOLTAGE OF THE BLACK AND

WHITE WIRES MUST BE NO

HIGHER THAN 130 VAC

Supply voltages for all gas ovens (except one 200 - 220V

ovenforexport)canrangefrom208 to240VAC,1phase.

Ampererequirementsforeachovencanbehandledviaa

fused disconnect switch or main circuit breaker.

Contact an electrician or the electric power supply com-

pany to remove the ‘high’ leg from the electric supply

line(s) to the oven.

NOTE: The electric supply installation must satisfy the

requirements of the appropriate statutory authority, such

as the National Electrical Code (NEC), ANSI/NFPA70,

In the junction box on the rear of the oven, connect one

208 - 240V supply line to the brownwire terminaland the

other 208 - 240V supply line to the blue wire terminal.

Connect the electric supply ground wire to the oven

ground lug located in the main junction box. If neces-

sary, have the electrician supply the ground wire. Do

NOT use the wiring conduit or other piping for ground

connections!

Figure 2-11. Typical Gas Oven Data Plate

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SECTION 2

INSTALLATION

Electrical Junction

Cover Plate

Figure 2-12. Junction Connection Box

Checktheovendataplate(Figure2-11)beforemakingany

gas supply line connections. The type of gas (natural or

propane)beingsuppliedtotheovenmustagreewithdata

on the oven data plate.

V. GAS SUPPLY FOR GAS HEATED

OVENS

WARNING

During gas line pressure testing, observe the

followingprecautions:

Certainsafetycoderequirementsexistfortheinstallation

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

of the installation standards. In addition, because a

PS540-Series oven is equipped with casters for accessi-

bility during servicing, the gas line connection shall be

madewithaconnectorthatcomplieswiththeStandardfor

ConnectorsforMovableGasAppliances,ANSIZ21.69(in

U.S.A.), or, if applicable, Connectors for Movable Gas

Appliances, CAN/CGA-6.16 (in Canada), as well as a

quick-disconnect device that complies with the Standard

for Quick-Disconnect Devices for Use With Gas Fuel,

ANSI Z21.41 (in U.S.A.), or, if applicable, Quick-Discon-

nectDevicesforUseWithGasFuel,CAN6.9(inCanada).

1. The oven and its individual shutoff valve

MUST be disconnected from the gas supply

piping system during any pressure testing of

that system at test pressures in excess of

1/2 psig (3.45kPa).

2. The oven MUST be isolated from the gas

supply piping system, by closing its individual

shutoff valve, during any pressure testing of that

system at test pressures equal to, or less than,

1/2 psig (3.45kPa).

One gas line connection method is shown in Figure 2-13;

however, the preceding requirements must be satisfied.

The90-degreeelbowandtheunionshowninFigure2-13

are not furnished; however, the flexible gas line is part of

the installation kit.

3. If incoming gas line pressure exceeds

14″w.c. (35mbar), a separate regulator MUST be

installed in the line on the inlet side of the safety

valve for the oven.

On an oven equipped with casters, a cable restraint

assembly must be installed to limit the movement of the

appliance,withoutdependingontheconnectorandquick-

disconnect device or its associated gas line installation.

ThelocationwheretheCableRestraintAssemblyistobe

attached to the oven is illustrated in Figure 2-8.

CAUTION

To prevent damaging the control valve regulator

of the oven during initial turn-on of gas, the

individual shutoff valve MUST be opened very

slowly. After initial turn-on of gas, the individual

shutoff valve should remain open except during

gas line pressure testing (refer to the preceding

WARNING) and during necessary servicing and

maintenanceprocedures.

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SECTION 2

INSTALLATION

The minimum gas line pressure at the input side of the

full-flow gas shutoff valve, when the oven burner is

operating on the high flame, MUST be, for natural gas,

6″ w.c. (14.9mbar), 1.13 kPa and for propane gas,

11″ w.c. (27.4mbar) 2.75 kPa. Sufficient pressure must

be available to provide for the maximum BTU consump-

tionratefortheoven:116.0mJ/h, 110,000BTU/hourfor

each PS540 Oven. For double oven installations, the

BTU/hour requirement for a single oven is doubled. For

triple oven installations, the BTU/hour requirement for

a single oven is tripled.

VI. CONVEYOR REAR STOP AND END

STOP INSTALLATION

Locate the conveyor rear stop and end stop in the

installationkit.Installtherearstopandendstopattheexit

end of the oven. See Figure 2-14.

To Gas Supply Pipe

Appliance

Connection

(Male Nipple)

Full Flow Gas

Shutoff Valve

90-deg.

ST. Elbow

Union

Flexible Hose

Figure 2-13. Flexible Hose Installation

Conveyor Rear Stop

Conveyor End Stop

Figure 2-14. Installing Rear and End Stops

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SECTION 2

INSTALLATION

NOTES

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SECTION 3

OPERATION

SECTION 3

OPERATION

I. CONTROL FUNCTIONS

Figure 3-1. PS540-Series Oven Control Functions

WARNING

The burner cannot operate and gas cannot flow

through the burner without electric power. Do

NOT attempt to operate the oven during a power

outage.

WARNING

A possibility of injury from rotating parts and

electric shock exists in this oven.

Never disassemble or clean the oven with the

BLOWER switch or any other oven control turned

“ON” or “I”. Turn “OFF” or “O” and lockout or

tagout all electric power to the oven before

attempting to clean or service this oven.

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SECTION 3

OPERATION

burnercannotlight,iftheairswitchdoesnotsenseairflow

off the main blower fan.

II. COMPONENT INFORMATION AND

LOCATION (Figures 3-1 and 3-2)

C. Heat Switch

A. Door Safety Switch

Turning the HEAT switch to “ON” or“I” will initially set up

the oven purge circuit. After approximately 30 seconds,

the burner lights. After the burner is lit, a flame sensor

sends a signal to the ignition module to stop the spark.

The burner will run unless the flame sensor does not

detect a flame or the heat switch is turned to the “OFF”

or “O” position.

The Door Safety Switch is located at the lower left side of

control panel opening. Opening the control panel door

permits this switch to open, disconnecting power to all

electrical controls.

CAUTION

Do NOT touch the wires going to this safety switch.

Current is always present.

TheHEATswitchisinserieswiththeburnerblowermotor

centrifugal switch, the high-temperature safety switch,

and the blower fan air pressure switch. All three safety

switches must be closed for gas to flow and the burner to

light.

B. Blower Switch

The blower switch has two positions. The switch must be

“ON” or “I” for the burner to come on and permit the oven

towarmup.Thefancirculatestheairthroughouttheoven

and must stay on during baking and during the cool down

cycle above 200°F (93°C) to prevent blower bearing

damage. To protect the blower motor and bearings a

thermostaticoverrideisbuiltintotheoven.Ifthetempera-

tureinsidetheovenisover180°F(82°C)themainblower

will continue to run after the blower switch is turned to the

“OFF” or “O” position.

D.TemperatureController

The temperature controller is a solid-state, on/off type to

maintain the operator-set temperature. The temperature

controllercontinuouslymonitorstheoventemperatureand

turns on the modulating solenoid valve in a gas-heated

oven. The heat is on for the time required to maintain a

constantoventemperature.

The temperature controller contains a low-limit switch

whichallowstheoventocooldownto200°F(93°C)before

shutting off the blower. A high-limit indication (ALM 1) will

appear on the display if the oven reaches 650°F (343°C).

An air pressure switch monitors the air flow from the

blower, acting as a safety interlock for the burner. The

Figure 3-2. Interior View of Machinery Compartment and Control Console

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SECTION 3

OPERATION

E. Conveyor

The on-off switch for the conveyor motor is on the control

panel. Also on the control panel is the digital conveyor

speed control. The digital control can be adjusted from 3

min. to 30 min. bake time (conveyor speed). Refer to

Figure3-3.

Conveyor speed is measured by the amount of time it

takes for an item to go through the bake chamber of the

oven.

MEASURING CONVEYOR SPEED.

See Figures 3-4 and 3-5.

Figure 3-3. Conveyor Speed Digital Control

To check conveyor speed, place a product item at the

entranceendofbakingchamberasshown.Timehowlong

it takes for the leading edge of the item to go from the

entrance end of the baking chamber to the exit end. This

should be the conveyor speed shown on the conveyor

speed digital control.

NOTE: In Figures 3-4 and 3-5, the oven shown is with the

conveyor running right to left.

WARNING

The burner will not operate and gas will not flow

through the burner without electric power. No

attempt should be made to operate the oven

duringpowerfailure.

WARNING

Possibility of injury from rotating parts and

electrical shock exist in this oven.

Figure 3-4. Product at entrance end of baking

chamber – BEGINNING OF TIMING

Never disassemble or clean the oven with the

blower switch or any other part of the oven

turned “ON” or “I”. Turn “OFF” or “O” and

lockout or tagout all electrical power to the

oven before attempting to clean or service

this oven.

Figure 3-5. Product at exit end of baking

chamber – END OF TIMING

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SECTION 3

OPERATION

5. Turn the HEAT switch (Figure 3-6) to the “ON” or “I”

position. This completes a circuit to supply electric power

totheburner.Whenanoventhathasnotbeeninoperation

for approximately 1/2 hour is turned on, it goes through a

30-second purge cycle. The burner blower motor will not

operateduringthetimetheblowerfanispurgingtheoven.

After 30 seconds, the burner blower motor starts, which

canbedetectedbyfeelingaslightvibrationwhentouched.

This permits the burner to light.

WARNING

OVEN MUST BE KEPT CLEAR OF

COMBUSTIBLES AT ALL TIMES.

III. STEP-BY-STEP OPERATION

Control Panel (On split belt ovens, two conveyor speed

controls are mounted on the control panel.)

Wheninoperation,theburneriseitheronloworhighflame.

Its flame-sensing electrode must be satisfied to keep the

bypass and gas valves open. If for some reason the

bypassflameisextinguished,theburnertriestorelightfor

90 seconds. If the burner flame does not relight in 90

seconds, the oven goes into automatic safety lockout.

A.StartupProcedures

Initial Startup

Check that the full-flow gas shutoff valve is “on”.

This valve is located outside the rear of the oven. See

Figures 2-3, 2-4, and 2-5.

To relight the oven, turn the HEAT switch to “OFF” or “O”

for 5 minutes. Then, repeat the Oven Startup procedure.

DailyStartup

1. TurntheBLOWERswitch(Figure3-6)tothe“ON”or“I”

position. This starts the main blower fan and the cooling

fan. The blower circulates air through the air fingers and

must stay on during the cooking or baking process.

6. Closefrontwindow.

7. Ovenwillreachabakingtemperatureof600°F(315°C)

in approximately 10 minutes. Allow the oven to cycle for

30minutesafterithasreacheddesiredbaketemperatue.

The oven is now ready for baking.

2. Check to see if the cooling fan (see Figure 1-8) is

operatingwhentheblowerswitch(seeFigure3-6)isturned

“ON” or “I”. The cooling fans cool the control components

and burner blower motor. The cooling fan, located at the

rear of the electrical control cabinet blows air into and

through the cabinet. Air is exhausted through the front of

thecabinetandalsooutthefrontoftheoven.RefertoDaily

Maintenance Section for fan intake checking procedure.

Power Failure

In case of power failure, turn off all switches; open oven

window and remove product. After power has been

reestablishedfollownormalstartupprocedure.

CAUTION

The burner will not operate and gas will not flow

through the burner without electric power. No

attempt should be made to operate the oven

duringpowerfailure.

IMPORTANTNOTE

The cooling fan operates when the BLOWER

switchisturned“ON”or“I”.Itmustoperatetokeep

the control console below 140°F (60°C).

B. ShutdownProcedure

3. TurntheCONVEYORswitch(Figure3-6)tothe“ON”or

“I” position. This starts the conveyor belt moving through

the oven. Set the conveyor speed for the desired baking

time. Refer to the following Procedures E, F and G.

1. TurntheBLOWERandHEATswitchesto“OFF”or“O”.

NOTE: Theblowerswillremainonuntiltheoventempera-

turecoolsdownto200°F(93°C)atwhichtimetheywillstop

automatically.

4. Set the temperature controller to the desired baking

temperature. See section on bake times to determine

desiredtemperature.

2. Make certain that there are no products left on the

conveyor inside the oven. Turn the CONVEYOR switch

to “OFF” or “O”.

NOTE: For complete temperature controller operation

instructions refer to Step C.

3. Turn off the main gas supply valve.

4. Open the oven window.

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SECTION 3

OPERATION

Figure 3-6. Control Panel

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SECTION 3

OPERATION

7. Wait for the oven to heat to the setpoint temperature.

Higher setpoint temperatures will require a longer wait.

The oven can reach a temperature of 500°F (232°C) in

approximately 5 minutes.

II. NORMAL OPERATION - STEP-BY-STEP

A.DailyStartupProcedure

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

on position. Check that the window is closed.

8. (Optional)PresstheTem-

perature ( ) key to show

2. Turn the "BLOWER"

(

) switch to the “ON”

the Actual Temperature

in the display, and wait

wait

("I") position.

for

for the "ACTUAL TEMP"

light to turn on. This al-

lows you to monitor the

oven temperature as it

rises to the setpoint.

3. Turnthe"CONVEYOR"

(

) switch to the

“ON” ("I") position.

9. Allow the oven to preheat for 10 minutes after it has

reached the set point temperature.

B. DAILYSHUTDOWNPROCEDURE

4. If necessary, adjust the

conveyor speed setting

1. Turnthe"HEAT"( )and

by pressing the

"BLOWER" ( ) swit-

pushbuttons on the con-

veyor speed controller to

change the displayed

bake time.

ches to the "OFF" ("O")

position. Note that the

blowers will remain in op-

eration until the oven has

cooled to below 200°F

(93°C).

5. Adjust the temperature

controller to a desired set

temperature, if neces-

sary.

wait

for

2. Make certain that there

are no products left on

the conveyor inside the

oven. Turn the "CON-

•

Press the Set Point

and Unlock keys at

the same time. Wait

forthe"SETPT"light

to turn on.

VEYOR" (

) switch to

the "OFF" ("O") position.

•

Press the Up Arrow

and Down Arrow

Keys as necessary

to adjust the set-

point.

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

4. After the oven has cooled and the blowers have turned

tothe“OFF”or“O”position, switch the circuit breaker/fuse

disconnect to the “OFF” or “O” position.

6. Turn the "HEAT" (

)

CAUTION

switch to the "ON" ("I")

position, and wait for the

"HEAT ON" light to turn

on.

In case of power failure, turn all switches to the “OFF”

("O") position, open the oven window, and remove

the product. After the power has been restored,

perform the normal startup procedure. IF THE OVEN

WASSWITCHEDOFFFORLESSTHAN5MINUTES,

WAIT FOR AT LEAST FIVE MINUTES BEFORE RE-

STARTINGTHEOVEN.

wait

for

The burner will not operate and gas will not flow

through the burner without electric power. No

attemptshouldbemadetooperatetheovenduring

a power failure.

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SECTION 3

OPERATION

Display

"HEAT ON"

Shows the Set Point

or the Actual Tem-

perature in degrees

Fahrenheit (F) or

Celsius (C).

Light

Lights when the

burner is in

operation.

"SP LOCK"

Light

Lights when the

set point is locked

out from changes.

This setting can

only be changed by

service personnel.

"SET PT"

(setpoint)

Light

Lights when the

set point is shown

in the display.

OVERTEMP

Light

"ACTUAL TEMP"

Lights when the oven

temperature is

Light

Lights when the Actual

Temperature is shown

in the display.

greater than 650°F

(343°C). Refer to

Quick Reference:

Troubleshooting in

this section.

Service Key

Serviceuse

only.

Temperature

Key

Press this key once

to view the Actual

Temperature in the

Display.

Set Point Key

Press this key

together with the

Unlock Key to allow

the Set Point to be

changed.

Changes can only be

made for 60 sec-

onds.

Unlock Key

Press this key

Up Arrow and Down

together with the Set

Point Key to allow the

Set Point to be

changed. Changes

can only be made for

60 seconds.

Arrow Keys

Press these keys to

adjust the Set Point up or

down. If the Set Point will

not change, refer to Set

Point Key and Unlock Key

in this section.

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SECTION 3

OPERATION

IV. QUICK REFERENCE: TROUBLESHOOTING

SYMPTOM

PROBLEM

SOLUTION

The oven temperature ex-

ceeded650°F(343°C), and

the burner was automati-

cally shut down.

•

Follow the procedures under Daily Shutdown Procedures in

this section to shut down the oven. Contact your Middleby

MarshallAuthorizedServiceAgenttodetermineandcorrectthe

cause of the condition to prevent damage to the oven.

light is lit, food product is

undercooked

Oven will not

turn on at all

Electrical power may not be

reaching the oven, or the

controls may be set incor-

rectly.

•

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

Check that the "BLOWER" ( ) Switch is in the “ON” ("I")

position. The burner cannot engage until the blowers are in

operation.

Oven shuts down shortly

after it is turned on

The gas burner did not light

within 90 seconds of turn-

ing the "HEAT" ( ) Switch

to the “ON” ("I") position.

This automatically en-

gages a safety lockout

mode.

•

Turn the "HEAT" ( ), "BLOWER" ( ), and "CONVEYOR"

(

)switches to the "OFF" ("O") position.

•

Wait for AT LEAST FIVE MINUTES before restarting the oven.

Repeat the Daily Startup procedure.

The oven did not reach

200°F (93°C) within 15 min-

utesofstartup,andtheoven

has stopped heating.

•

Turn the "HEAT" ( ), "BLOWER" ( ), and "CONVEYOR"

(

)switches to the "OFF" ("O") position.

•

Wait for AT LEAST FIVE MINUTES before restarting the oven.

Repeat the Daily Startup procedure.

appears in display,

oven is not heating

Controls may be set incor-

rectly.

•

Check that the Set Point is correctly set.

Oven will not heat

Checkthatboththe"BLOWER"( ) and"HEAT"( )Switches

are in the “ON” ("I") position.

•

If the oven still will not heat,turn the "HEAT" ( ), "BLOWER"

(

), and "CONVEYOR" (

)switches to the "OFF" ("O")

position.

•

Wait for AT LEAST FIVE MINUTES before restarting the oven.

Repeat the Daily Startup procedure. Check that the Set Point

is above 200°F (93°C).

Oven is operating, but

little or no air is blowing

from air fingers

Air fingers may have been

reassembled incorrectly

after cleaning.

•

Turn the oven to the “OFF” or “O” position, and allow it to cool.

Disconnect electrical power to the oven.

Refer to Section 4, Maintenance, for instructions on reassem-

bling the air fingers.

Conveyor moves with a

jerky motion, or will not

move at all

Conveyor may be jammed

on an object in the oven, or

conveyor belt or drive chain

tension may be incorrect.

•

Turn the oven to the “OFF” or “O” position, and allow it to cool.

Disconnect electrical power to the oven.

•

Check if the conveyor is blocked by an object inside the oven.

Refer to Section 4, Maintenance, for instructions on checking

the conveyor and drive chain tension.

Food products are

overcooked or

undercooked.

Controls may be set incor-

rectly.

•

Check that the set temperature and bake time settings are

correct.

IFTHESESTEPSFAILTORESOLVETHEPROBLEM,CONTACTYOURLOCALMIDDLEBYMARSHALL

AUTHORIZED SERVICE AGENT. A SERVICE AGENCY DIRECTORY IS SUPPLIED WITH YOUR OVEN.

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SECTION 4

MAINTENANCE

SECTION 4

MAINTENANCE

WARNING

Possibility of injury from rotating parts and electrical

shock exist in this oven. Turn off and lockout or tagout

electrical supply to oven(s) before attempting to

disassemble, clean or service oven(s). Never disas-

semble or clean the oven with the blower switch or any

other part of the oven turned on.

WARNING

Before performing any maintenance work or cleaning,

turn main power switch off.

CAUTION

When cleaning do not use any abrasive cleaning

materials or water spray, wipe clean only. Never use a

water hose or pressurized steam cleaning equipment

when cleaning this oven.

NOTICE

If the oven is to be removed from its installed location

for servicing, perform the following procedure:

1. Switch off the oven and allow it to cool. Do NOT

service the oven while it is warm.

2. Shut off main manual gas valve and disconnect

gas connector from oven.

3. Turn off main circuit breakers and disconnect

connector from oven.

4. Turn the adjustable legs to put weight on the

casters.

5. Move oven to desired location for servicing.

6. When servicing is complete, move oven to original

location.

7. Adjust legs to level oven and take weight off

casters.

8. Connect electrical and gas connectors to oven.

9. Turn on manual gas valve.

10. Turn on main circuit breakers.

11. Follow normal startup instructions.

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SECTION 4

MAINTENANCE

D. Crumb Pans (Figure 4-2)

I. MAINTENANCE - DAILY

Removeandcleanthecrumbpanateachendoftheoven.

Each crumb pan can be removed by sliding it out, as

shown in Figure 4-2. Reinstall the crumb pans after

cleaning.

A. Exterior

Everyday you should clean the outside of the oven with a

soft cloth and mild detergent.

E. Window

The window can be cleaned daily while it is in place.

WARNING

Vent Grille

Never use a water hose or pressurized steam

cleaning equipment when cleaning the oven.

B. Cooling Fan

1. TWO COOLING FAN GRILLES AT THE REAR OF

EACH OVEN CONTROL COMPARTMENT MUST BE

CLEANED DAILY - Clean grilles with a stiff nylon type

brush.

Cooling Fan Grille

2. Check the air intake of the cooling fan daily. The best

time to check is right after starting the oven.

IMPORTANTNOTE

Thecoolingfanoperateswhentheblowerswitch

is turned to “ON” (“I”). It must operate to keep the

electrical control cabinet below 140°F (60°C).

Cooling Fan Grille

WARNING

IF FAN BLADE IS NOT ROTATING, BROKEN,

OR FAN ASSEMBLY IS MISSING FROM MAIN

BLOWERMOTORSHAFT,DONOTOPERATE

OVEN. REPLACE COOLING FAN BLADE

BEFOREOPERATINGOVEN.Seriousdamage

could be done to the burner blower motor and/or

solid-state electrical components if oven is

operated while cooling fan is not running or vent

grille is plugged.

Figure 4-1. Oven Cooling Fans

3. Using a stiff nylon brush clean control compartment

ventgrille.Hotairfromcontrolcompartmentexitsfromthis

grille.

C. Conveyor Belt (Figure 4-2)

Everyday, just after starting the oven, stand at the

unloading end of the conveyor, and with a brush, remove

foodparticles(crumbs, etc.)clingingtotheconveyorbelt,

brushing them into the crumb pan.

Figure 4-2. Conveyor Belt and

Crumb Pan Cleaning

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SECTION 4

MAINTENANCE

deposits use a non-caustic cleaner that will not react with

the aluminized finger manifold surfaces.

II. MAINTENANCE - MONTHLY

NOTE: The oven interior may require cleaning more

than once a month depending on the volume of

baking.Tocleantheinterior,youhavetodisassemble

some parts of the oven.

You can order non-caustic cleaner from your local autho-

rizedMiddlebyMarshallPartsDistributorinthequantities

listed below:

Part #

Quantity

When cleaning your Series PS540 Oven note the

following:

27170-0244

27170-0246

Case of Quarts (6)

Case of Gallons (4)

PRECAUTIONS-

1. Do not use excessive water or saturation of oven

insulation will occur.

A. Removing Conveyor From Oven For Cleaning

1. Remove crumb pans as shown in Figure 4-2.

2. Do not use a caustic oven cleaner or the aluminized

finger manifold surfaces will be severely damaged.

2. Remove upper and lower end plugs from each end of

ovenbyremovingthetwowingscrewsfromeachendplug.

When cleaning your oven, first remove all heavy debris

withavacuumcleaner.Useadampclothforlightcleaning.

For heavier cleaning of baked on grease and carbon

3. Remove the conveyor end stop and the conveyor rear

stop(Figure4-3).

Figure 4-3.

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SECTION 4

MAINTENANCE

4. Remove conveyor drive chain cover as shown.

5. Removetensionfromdrivechainbyliftingandpushing

the conveyor slightly into the oven. Remove drive chain

from conveyor drive sprocket as shown.

NOTE: The split belt conveyor assembly can only be

removed from the drive end of the oven.

6. Begin sliding conveyor out of the oven as shown.

Figure 4-4.

Figure 4-7.

7. Continue sliding the conveyor completely out of the

oven,folditinhalfandthenplaceittothesideforcleaning.

Be careful not to bump drive sprocket while handling

conveyor or damage may result to drive shaft.

Figure 4-5.

Figure 4-8.

CAUTION

Be careful not to bump the drive sprocket while

handling the conveyor, to avoid damaging the

drive shaft.

Figure 4-6.

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SECTION 4

MAINTENANCE

B. Air Fingers Disassembly For Cleaning

1. Astheairfingersareremoveduseafeltpentomarkall

partsofthefingers.Thisincludesthefingermanifold,inner

plate and the outer plate (refer to Figure 1-9). If a blank or

choke plate is used, mark that plate also. Fingers are

markedintheordershown;asviewedfromthefrontofthe

oven. (The marks for an upper oven should be preceded

with a “U”, example UB1, UT2, etc.)

Standard Fingers

2. Slide blank plates straight out.

Figure 4-10.

4. Withairfingersout,placetheminanuprightpositionto

remove the outer plate.

5. Gentlystepothelipofthefingerandpulltheouterplate

off.

Figure 4-9.

3. Remove air fingers.

NOTE:Someovenusersrequireacustomfingerarrange-

ment where the quantity of air fingers may vary.

You can remove top and bottom fingers and blank plates

from each or either end. It is highly recommended that

each finger be marked before removing so it is placed in

exactly the same position when reassembled

(refer to step 1).

Removetheairfingers,pullthefingeratthebackside-pull

straight out.

Figure 4-11.

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SECTION 4

MAINTENANCE

6. Toremovetheinnerplate,pulltheplateoutandthenup.

1. Remove the window by opening the window and un-

screwing the window knobs from each end.

Figure 4-15.

2. Push the window all the way inside the oven, making

sureitisclearoftheframe.Now,turnthewindowsideways

while inside the oven and then remove it. This will avoid

breakingthewindow.

Figure 4-12.

7. The outer finger plate is stainless and may be cleaned

by either soaking in a hot, strong detergent solution or

using a caustic cleaner. The conveyor belt can also be

cleaned in the same way.

Figure 4-16.

D. Reassembly of Air Fingers

Figure 4-13. Standard Lower Finger

1. Air fingers are made up of one inner plate, one outer

plateandthefingerhousingmanifold.Besuretomatchup

the markings (T1, T2, T3, etc.) on all the parts of the air

fingers as you are reassembling.

Figure 4-14. Standard Upper Finger

C. Cleaning the Window

Thewindowcanbecleanedinplace.Ifitneedsathorough

cleaning it may have to be removed.

Figure 4-17.

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SECTION 4

MAINTENANCE

2. Reassembletheinnerplate.Keepyourfingersclearso

you won’t pinch them. The inner plate of a finger will only

go in one way because of its design.

3. Replace the outer plate by placing your hands flat on

the top of the plate and pushing down. Keep your fingers

clear so you won’t pinch them.

Figure 4-19.

IMPORTANT: Only M6 Fingers fit in the bottom

row. All M3 and M1 finger cover plates have

extended lips at front. This extended lip will not

allowthesefingerstobeinstalledinthebottomrow.

Figure 4-18.

IMPORTANT: When inserting fingers the tab on

theouterplatemustbeinthegrooveasshownin

Figure4-20.Thereisablockingtabontheoutside

of the groove which will prevent inserting the

finger in the groove if the outer plate is moved

away from the flange of the finger manifold.

4. Replace the air fingers by pushing in at the back side.

Remember to replace them according to the numbers

marked on them when they were removed. They must go

back in the same way they came out.

Extended Lip

Tab on

Outer Plate

Flange of

Finger Manifold

Tab on

Outer Plate

Figure 4-20.

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SECTION 4

MAINTENANCE

5. Install fingers and blank plates correctly with edges

interlocked and no space between edges.

Incorrect - Too

Much Space

Top Finger

Blank Plate

Tab on Outer Plate of Finger

Located in Groove

Incorrect - Too

Much Space

Top Finger

Blank Plate

Tab on Outer Plate of Finger

Located in Groove

Correct -

Edges Overlap

Completely

Top Finger

Blank Plate

Tab on Outer Plate of Finger

Located in Groove

Figure 4-21.

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SECTION 4

MAINTENANCE

E. Reinstall End Plugs

1. Reinstall lower end plug. Be sure to tighten two wing

screws on the end plug.

2. Reinstall conveyor.

3. Reinstall upper end plug. Be sure to tighten two wing

screws on the end plug.

Figure 4-22.

Figure 4-23.

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SECTION 4

MAINTENANCE

F. ConveyorReassemblyIntoOven

G. CheckingConveyorBeltTension

1. Lift conveyor and position it in oven as shown.

WARNING

NOTE: Conveyor assembly may be inserted into either

end of oven. If it is to be installed from the non-drive end

oftheoventhedrivesprocketassemblymustberemoved

as shown in conveyor disassembly section.

Ovenconveyorbeltmustbecoolwhenadjusting

belt. Do not adjust belt if HOT.

1. With the conveyor assembly in the oven, stand at one

endofconveyorandchecktensionbyliftingtheconveyor

belt at the center of the oven chamber opening. The belt

should not lift higher that 3″ to 4″ (75mm to 102mm).

NOTE: Split belt conveyors can only be inserted from the

drive end of the oven.

2. Adjust conveyor belt tension screws (located on left

end of oven) for the 3″ to 4″ (75mm to 102mm) deflection

asshowninFigure4-26.Ifthereispropertension,proceed

to “J. Attaching Drive Chain”. If belt is still too loose,

continue to step 3 below.

3. If conveyor belt is still not under proper tension, an

entirelinkmustberemoved. Usethefollowingprocedure

“H. Conveyor Belt Link Removal” to remove a link. If

conveyor belt is under proper tension proceed directly to

“J. Attaching Drive Chain”.

Figure 4-24.

2. Reinstall the conveyor rear stop. Reinstall the con-

veyor end stop.

Conveyor Rear Stop

Conveyor End Stop

Figure 4-26.

Figure 4-25.

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SECTION 4

MAINTENANCE

H. ConveyorBeltLinkRemoval

4. Unhook the link to be removed.

1. Using long nose pliers, an entire link can be removed

with the conveyor assembly either in or out of the oven.

Position master links at end of conveyor as shown in

Figure4-27.

5. Pull up on the belt link section and remove. Do not

discard the link removed as it may be used for making

spare master links.

NOTE: If a section of the conveyor belt is being replaced

it should be done now. Remove the links that need

replacingandusethesectionofconveyorbeltfurnishedin

your installation kit to replace them.

Master

Links

Figure 4-27.

2. Using long nose pliers, unhook master links at left end

of conveyor as shown in Figure 4-28.

Figure 4-30.

NOTE: Before connecting the inside master links, notice

thattheselinkshaveacorrectposition(Figure4-31). The

link at the right is in the correct (horns up) position for

insertingintotheconveyorbelt.Thehornsfacingdownare

in the incorrect position.

Correct

Position

Incorrect

Position

Figure 4-28.

3. Remove the outside master links on the right and left

sides of the conveyor belt as shown in Figure 4-29.

Figure 4-31.

Figure 4-29.

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SECTION 4

MAINTENANCE

6. Reconnect the inside master links (Figure 4-32.)

I. ReplacingConveyorBelt

If a section of the conveyor belt needs replacing it can be

done with the conveyor assembly either in or out of the

oven. The section of the conveyor belt furnished with the

oven in the installation kit may then be used to replace a

section.Followtheprecedingprocedure“H.Conveyorbelt

link removal” which outlines the disassembly procedure.

J. AttachingDriveChain

1. Ifdrivesprocketassemblywasremovedreassembleit

into the conveyor drive shaft. Be sure flat on end of drive

shaft aligns with set screw in conveyor shaft collar. Once

in place tighten 3/32″ set screw.

2. Lift conveyor and install drive chain to conveyor drive

sprocket and motor sprocket.

Figure 4-32.

NOTE: The outside master links have right and left sides

to them. The right edge master link has an open hook

facingyouasshowninFigure4-33.Thiswillmatchupwith

theouteredgesoftheconveyorbelt.Rememberthishook

travels backwards on the conveyor.

Direction of travel

Figure 4-35.

Figure 4-33.

3. The angle plate located on the underside of the con-

veyor must be against the lower end plug. This is true on

both sides of oven.

7. Reconnect the outside master links.

8. Replace all parts removed from the oven.

CrumbPan

Mounting

Bracket

Figure 4-34.

LowerEndPlug

Figure 4-36.

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SECTION 4

MAINTENANCE

4. Reassemble conveyor drive chain cover and then

reassemble the bottom cover to the drive chain cover.

III. MAINTENANCE - EVERY 3 MONTHS

Install both upper end plugs.

WARNING

ShutOFFallelectricalpowerandlock/tagoutthe

switch before attempting maintenance work.

Shut OFF gas supply to oven.

NOTE: It is recommended that the 3-month mainte-

nancebeperformedbyanauthorizedMiddlebyMarshall

technician.

Cleaning the Blower/Fan Motor

To gain access to the blower/fan motor, open the control

cabinet door by removing the three screws. Clean the

motor,burnerblowermotor,theconveyordrivemotorand

thesurroundingarea,usingeithercompressedairorCO₂.

Thoroughly blow out the motor compartment and vents

insidethemotor(Figure4-38).Failuretodothiscancause

premature failure of blower fan motor.

Figure 4-37.

CAUTION

Not cleaning the blower/fan motor properly can

causeprematurefailure.

Figure 4-38.

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SECTION 4

MAINTENANCE

B. ElectricalTerminals

CAUTION

Open the control cabinet door by removing the three

screwsfromthecontrolcabinetdoor.Tightenallelectrical

control terminal screws including the electrical contactor

terminal screws as shown in Figure 4-39.

Overtighteningthebeltwillcauseprematurebearing

failure and possible vibration problems. A spare

belt is located inside the control compartment on

the rear wall.

3. Whenreplacingthebelt,loosenthetensionadjustment

bolts (Figure 4-42) on the motor mounting bracket. Next,

pullbackonthemotor.Retightenadjustmentbolts.Donot

overtighten because the fan bearings may be damaged.

Figure 4-39.

C. Ventilation

Figure 4-41.

Check that the air circulation throughout the oven is not

blocked and is working properly.

D. CheckingtheBlower/FanBelt

1. Check the main blower/fan belt for proper tension and

wear. Togainaccess,loosenthesixscrews(Figure4-40)

of the rear shroud and lift shroud cover up and off.

2. The fan belt should deflect no less than 1″ (25mm) at

the center (Figure 4-41) and have no cracks or excessive

wear.

Figure 4-42.

Figure 4-40.

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SECTION 4

MAINTENANCE

E. Blower Fan Shaft Bearing Lubrication

3. Remove the conveyor adjustment bolts to allow the

idler brackets to swing free.

CAUTION

Over-greasing damages the bearing seals and

acceleratesgreaseloss,whichshortensbearing

life. Wipe off any excess grease on and around

thebearing.Reinstalltherearshroudtoallowthe

oven to operate

Greasethetwo(2)mainblowerfanshaftbearings(Figure

4-43),usingaspecialgrease(MMP/N17110-0015lithium-

base,high-temperaturegrease).ONLYONESTROKEof

a grease gun is required for each bearing.

Figure 4-44.

4. Droptheidlershaftassemblyclearoftheframethrough

the front frame slot.

Figure 4-43.

Upon completing the fan belt check (or replacement) and

thebearinglubrication,reinstalltherearshroud,fastening

it with six screws of the rear shroud.

Figure 4-45.

F. Split-belt Conveyor Shaft Cleaning

5. Pullthefrontandrearshaftsapartandapplyoiltoboth

the extended shaft and the interior of the hollow shaft.

Using a rag, wipe oil off parts. Repeat until shafts are

clean. Apply more oil to shafts then reassemble.

It is very important that the split-belt conveyor drive and

idler shafts are removed from the conveyor frame for

cleaningandlubrication.

CAUTION

Use a turbine oil or light machine oil. DO NOT

USE WD40 or similar product. These oils

evaporate and cause the shafts to seize.

1. Perform the conveyor removal steps described in

Monthly Maintenance, paragraph “A”. After the conveyor

is removed, lay it on a flat surface.

2. Remove the two conveyor belts by disassembling the

conveyor master links, as described in Monthly Mainte-

nance, paragraph “H”. Then, remove the two conveyor

belts by rolling them up.

Figure 4-46.

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SECTION 4

MAINTENANCE

6. Makesurebronzewasherisinbetweenthetwohalves.

9. Loosen the split locking collar.

Figure 4-47.

7. Place the idler shaft assembly back into place and

reinstall the adjustment screws.

Figure 4-50.

10. Remove drive shafts by sliding to right then lifting the

left side. Follow cleaning and lubricating procedures out-

lined in Steps 4-6.

Figure 4-48.

Figure 4-51.

8. Loosenthesetscrewoneachconveyordrivesprocket

and remove sprockets.

11. Reassemble conveyor drive shafts into frame, mak-

ing sure nylon spacer is in place.

Figure 4-49.

Figure 4-52.

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SECTION 4

MAINTENANCE

12. Slide shaft assembly to right side, holding assembly

in place. Slide split locking collar to the left side and

tighten.

13. Sliderearconveyordrivesprocketontoshaft.Tighten

thesetscrewofthisdrivesprocketuntilitextendsintothe

hole of the hollow shaft. It should NOT touch the inner,

solid shaft. Check to see that only the rear shaft moves

whenthesprocketisturned.Ifbothshaftsmove,youhave

tightened the set screw too tight. Loosen the set screw

until only the rear shaft moves when the sprocket is

turning.

Figure 4-53.

14. Insert adaptor bushing into remaining drive sprocket

thenplaceontoshaft. Makesurenylonspacerisinplace.

Tightensetscrewmakingsurescrewgoesthroughslotin

adaptor bushing and locks onto shaft.

15. Thread conveyor belts back onto frame making sure

the links will be traveling in the proper direction.

16. Follow conveyor reassembly instructions in Monthly

MaintenanceParagraph“F”.

NOTE: Itisrecommendedthatthe6MonthMaintenance

schedulebeperformedbyaMiddlebyMarshallauthorized

service technician.

IV. MAINTENANCE - EVERY 6 MONTHS

Figure 4-54.

A. CheckbrushesonD.C.conveyormotor,whenwornto

less than 1/10″ (2.4mm), replace the brushes.

B. Clean and inspect the burner nozzle and electrode

assembly. Also check your oven venting system.

C. Checkconveyorshaftbushingsandspacers.Replace

themiftheyareworn.SeeFigure6-5,ConveyorExploded

Drawing, items 15, 30 and 31 or Figure 6-6, Split Belt

Conveyor, items 19, 23, 31, 35 and 36.

IMPORTANT NOTICES:

• The installation, startup and changes required

whenchangingfromonegastypetoanothercanbe

performedonlybyanauthorizedservicetechnician.

CANADIAN REGULATIONS PROHIBIT

CHANGING AN OVEN’S OPERATION FROM

ONE GAS TO ANOTHER.

Figure 4-55.

• Installation of replacement parts requiring access

to the interior of the oven is permitted only by an

authorized service technician.

• If there are any problems with the operation of the

oven, the authorized service technician must be

called.

• It is suggested to obtain a service contract with a

manufacturer’sauthorizedservicetechnician.

Figure 4-56.

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SECTION 4

MAINTENANCE

KEY SPARE PARTS KIT

parts that can reduce serious downtime and loss of

production, if a failure occurs.

An oven can be purchased with a Key Spare Parts Kit

(Figure4-56).(Thekitcanbepurchasedwhentheovenis

ordered, or later, from a Middleby Marshall Authorized

Parts Distributor). The kit contains many of the crucial

Replacementpartsforthiskitcanbepurchasedfromyour

Middleby Marshall Authorized Parts Distributor.

PS540-SERIES GAS OVEN KEY SPARE PARTS KIT, p/n 36805 (Figure 4-56)

ITEM

PARTNO.

47321

ENGLISHDESCRIPTION

TemperatureController

Blower/FanMotor

QUANTITY

44687

47797

ConveyorDriveMotor

ConveyorSpeedControl

Thermocouple

37337

33812-3

41647

ModuleM420

50275

Burner & Motor Assembly

Ignition Control Module (kit)

50239

Figure 4-56. Key Spare Parts Kit, p/n 36805

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SECTION 5

TROUBLESHOOTING

SECTION 5

TROUBLESHOOTING

PROBLEM:

OVEN BLOWER AND CONVEYOR OPER-

ATE, YET THE OVEN IS NOT HEATING

PRODUCTS ARE OVERCOOKED

OR UNDERCOOKED

Reset the temperature controller

to a new setting (above 200°F),

after turning the BLOWER switch

to off for 30 seconds.

Check for correct

setting on tempera-

ture controller.

Check for correct

setting of conveyor

speed control.

Turn temperature

control to correct

setting.

Start the oven again. If the oven still does not

heat, call your Middleby Marshall Service Agency.

Set the conveyor speed

control at correct setting.

Verify the food

preparation process.

PROBLEM:

CONVEYOR WILL NOT HOLD PROPER

SPEED OR WILL NOT RUN AT ALL

If products still cook incorrectly,

call your Middleby Marshall

Service Agency.

Check whether the conveyor is

jammed on something in oven.

PROBLEM:

OVEN DOES NOT HEAT

Check for proper tension of conveyor drive

chain and conveyor belt. Refer to Section 4 for

correct procedure.

Check to see if both BLOWER

switch and HEAT switch are in

the “ON” or “I” position.

Check that the conveyor

drive sprocket is tight.

If oven does not heat, call your

Middleby Marshall Service Agency.

If conveyor still does not run correctly, contact

your Middleby Marshall Service Agency.

PROBLEM:

BLOWER MOTOR IS RUNNING, YET LITTLE

OR NO AIR BLOWS FROM AIR FINGERS

PROBLEM:

OVEN DOES NOT TURN ON WHEN ITS

SWITCHES ARE TURNED ON

Air fingers reassembled incorrectly,

after cleaning.

Check that all electric supply switches are set to

the “ON” or “I” position. Then, start the oven.

Assemble air fingers correctly, after cleaning.

Refer to Section 4 procedure, or call your

Middleby Marshall Service Agency.

If oven still will not start, contact your Middleby

Marshall Service Agency.

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SECTION 5

TROUBLESHOOTING

NOTES

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SECTION 6

PARTS LIST

SECTION 6 - PARTS LIST

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SECTION 6

PARTS LIST

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SECTION 6

PARTS LIST

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SECTION 6

PARTS LIST

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SECTION 6

PARTS LIST

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SECTION 6

PARTS LIST

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SECTION 6

PARTS LIST

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SECTION 6

PARTS LIST

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SECTION 6

PARTS LIST

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SECTION 6

PARTS LIST

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SECTION 6

PARTS LIST

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SECTION 6

PARTS LIST

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SECTION 6

PARTS LIST

(TSHOWN)

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SECTION 6

PARTS LIST

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SECTION 6

PARTS LIST

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SECTION 6

PARTS LIST

NOTES

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SECTION 7

ELECTRICAL SCHEMATICS

SECTION 7

ELECTRICAL SCHEMATICS

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SECTION 7

ELECTRICAL SCHEMATICS

NOTES

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SECTION 7

ELECTRICAL SCHEMATICS

NOTES

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SECTION 7

ELECTRICAL SCHEMATICS

NOTES

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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

otherthanyourMiddlebyMarshallAuthorizedServiceAgentmayvoidyourwarranty.

NOTICE

UsinganypartsotherthangenuineMiddlebyMarshallfactorymanufacturedpartsrelieves

themanufacturerofallwarrantyandliability.

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

serviceintheindustry.

MiddlebyCookingSystemsGroup•1400ToastmasterDrive•Elgin,IL60120•USA•(847)741-3300•FAX(847)741-4406

24-Hour Service Hotline: 1-(800)-238-8444

www.middleby.com

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