Middleby Marshall PS540-Series Electric Ovens: English ® A MIDDLEBY COMPANY owner's operating & installation manual PS540-Series OVENS Model PS540E PS540 (Double) ©2006 Middleby Marshall Inc. PS540 (Single) PS540 (Triple) Part No. 51415 Price $30.
WARNING FOR YOUR SAFETY, DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. WARNING Improper installation, adjustment, alteration, service, or maintenance can cause property damage, injury, or death. Read the installation, operation, and maintenance instructions thoroughly before installing or servicing this equipment.
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’s obligation under this warranty shall be limited to replacing or repairing, at Seller’s option, without charge, F.O.B.
TABLE OF CONTENTS TABLE OF CONTENTS (Continued) Page SECTION 1 I. MODEL IDENTIFICATION .............................................. 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 ......
SECTION 1 DESCRIPTION SECTION 1 DESCRIPTION I. MODEL IDENTIFICATION The Middleby Marshall PS540-Series may be used either as a single oven or stacked for use as double or triple ovens. The major difference between the oven models in this series is the width of the conveyor. A single PS540-Series Oven (Figure 1-1) is mounted on a base pad with legs and casters. A double oven (Figure 1-2) consists of two, stacked, single ovens. A triple oven (Figure 1-3) consists of three stacked single ovens.
SECTION 1 DESCRIPTION PS540 SERIES OVEN SPECIFICATIONS Conveyor Belt Width 32″ (813mm) Heating Zone Length 40-1/2″ (1028mm) Baking Area Square Feet 9 sq. ft. (0.84 sq. m.
SECTION 1 DESCRIPTION II. PRINCIPLE OF AIR FLOW reflect more heat. This is the reason that the inside of a PS540-Series Oven is light in color: To reflect more heat back onto the food product. The fan-style blower draws air into the oven plenum where it is heated. The blower then pushes the hot air through the air fingers into the baking chamber. Each air finger contains an inner plate and outer plate that form the hot air into jets, distributing it across a conveyor belt on which the food product rides.
SECTION 1 DESCRIPTION II. PRINCIPLE OF AIR FLOW (Continued) B. Air Fingers Series ovens used to bake pizza have four bottom fingers and two top fingers. For special product baking requirements, 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.
SECTION 1 DESCRIPTION III. COMPONENT FUNCTION (Figure 1-6) Figure 1-6.
SECTION 1 DESCRIPTION III. COMPONENT FUNCTION A. Conveyor Motor and Conveyor Belt The conveyor belt is driven by a variable-speed electric motor (Figure 1-7) operating through a gear reducer. The motor speed is controlled by a digital control. The stainless-steel wire belt can travel in either direction at variable rates ranging from 3 minutes to 30 minutes; this is the time that a product can take to pass through the oven. B. Blower Fan The blower fan is located at the rear of the oven.
SECTION 1 DESCRIPTION Figure 1-8.
SECTION 1 DESCRIPTION F2. Blank Plates 1. Blank Plates- The Blank Plates are available to install on the plenum where an air finger is not required. Half Blank Plate Outer Plate Blank Plate Inner Plate Finger Manifold Assembly Baffle Figure 1-9. Blank Plates (two sizes) and an Air Finger.
SECTION 2 INSTALLATION SECTION 2 INSTALLATION NOTE: 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. I. UNLOADING Your Middleby Marshall PS540-Series Oven is shipped partially assembled. It will arrive in a carton on a crate.
SECTION 2 INSTALLATION PS540 OVEN INSTALLATION REQUIRED KITS AND EQUIPMENT TYPE OF INSTALLATION PS540 Gas Oven Installation Kit P/N 50663 PS540 Single Oven Option Base w/15″ Legs, Casters & Top Kit P/N 34832 PS540 Single Oven 1 1 PS540 Double Oven 2 PS540 Triple Oven 3 PS540 Double Oven Option Base w/6″ Legs, Casters & Top Kit P/N 34833 PS540 Double Oven Option Base w/Casters & Top Kit P/N 34831 1 1 PS540 Triple Oven Option Base w/Casters & Top Kit P/N 51139 1 PARTS LIST FOR SERIES PS540 GAS
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/N 34832 ITEM NO. 1 2 3 4 5 6 7 8 9 10 QTY 1 4 2 2 32 32 32 4 1 1 PART NO.
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/N 34833 ITEM NO. 1 2 3 4 5 6 7 8 9 10 QTY 1 4 2 2 32 32 32 4 1 1 PART NO.
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/N 51139 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 QTY 1 4 2 2 4 4 32 32 32 16 8 8 8 4 1 1 PART NO.
SECTION 2 INSTALLATION Figure 2-5.
SECTION 2 INSTALLATION Figure 2-6.
SECTION 2 INSTALLATION Figure 2-7. MODEL TRIPLE OVEN DIMENSIONS GAS INLET ELECTRICAL JUNCTION BOX RECOMMENDED MINIMUM CLEARANCES: 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 Install the restraint cable assembly on the oven, as shown in Figure 2-6. Figure 2-8.
SECTION 2 INSTALLATION UTILITY ROUGH-IN DIMENSIONS AND POSITIONING FOR PS540-SERIES OVENS 5 WARNING DO NOT USE CONDUIT OR GAS LINE FOR GROUND CONNECTION. ON 6 OFF 2 3 1 24" 610mm 2 CAUTION 6 IT IS REQUIRED THAT THE OVEN BE PLACED UNDER A VENTILATION HOOD FOR ADEQUATE AIR SUPPLY AND VENTILATION. ON 27" 686mm OFF 2 3 2 4 13-1/2" 343mm 24" 610mm ELECTRIC AND GAS SUPPLY TO BE PROVIDED BY CUSTOMER Suggested dimensions are shown; utility code requirements supersede any factors shown.
SECTION 2 INSTALLATION II. VENTILATION GUIDELINES VENTILATION HOOD A mechanically driven ventilation system is required for the PS540 Series Middleby Marshall conveyorized electric ovens. The minimum hood canopy dimensions are outlined below. 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.
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 made via the electrical junction box on the rear of the oven (Figure 2-12).
SECTION 2 INSTALLATION VI. CONVEYOR REAR STOP AND END STOP INSTALLATION Locate the conveyor rear stop and end stop in the installation kit. Install the rear stop and end stop at the exit end of the oven. See Figure 2-13. Conveyor Rear Stop Middleby Marshall Conveyor End Stop Figure 2-13.
SECTION 3 OPERATION SECTION 3 OPERATION I. CONTROL FUNCTIONS Figure 3-1. PS540-Series Oven Control Functions 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.
SECTION 3 OPERATION II. COMPONENT INFORMATION AND LOCATION (Figures 3-1 and 3-2) burner cannot light, if the air switch does not sense air flow off the main blower fan. A. Door Safety Switch C. Heat Switch 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. Turning the HEAT switch to “ON” or“I” will initially set up the oven purge circuit.
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 Figure 3-3. 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.
SECTION 3 OPERATION 4. Set the temperature controller to the desired baking temperature. See section on bake times to determine desired temperature. WARNING OVEN MUST BE KEPT CLEAR OF COMBUSTIBLES AT ALL TIMES. NOTE: For complete temperature controller operation instructions refer to Step C. III. STEP-BY-STEP OPERATION 5. Turn the HEAT switch (Figure 3-6) to the “ON” or “I” position. This completes a circuit to supply electric power to the electric heating system.
SECTION 3 OPERATION 4. Open the oven window. Figure 3-6.
SECTION 3 OPERATION II. NORMAL OPERATION - STEP-BY-STEP 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. 8. (Optional) Press the Tem- A.Daily Startup Procedure 1. Check that the circuit breaker/fused disconnect is in the on position. Check that the window is closed. 2. Turn the "BLOWER" ( ) switch to the “ON” ("I") position. 3. 4. 5. 6.
SECTION 3 OPERATION "HEAT ON" Light Display Shows the Set Point or the Actual Temperature in degrees Fahrenheit (F) or Celsius (C). 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" Light Lights when the oven temperature is greater than 650°F (343°C).
SECTION 3 OPERATION IV. QUICK REFERENCE: TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION The oven temperature exceeded 650°F (343°C), and the burner was automatically shut down. • Follow the procedures under Daily Shutdown Procedures in this section to shut down the oven. Contact your Middleby Marshall Authorized Service Agent to determine and correct the cause of the condition to prevent damage to the oven.
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 disassemble 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.
SECTION 4 MAINTENANCE I. MAINTENANCE - DAILY D. Crumb Pans (Figure 4-2) A. Exterior Remove and clean the crumb pan at each end of the oven. Each crumb pan can be removed by sliding it out, as shown in Figure 4-2. Reinstall the crumb pans after cleaning. Everyday you should clean the outside of the oven with a soft cloth and mild detergent. E. Window WARNING The window can be cleaned daily while it is in place. Never use a water hose or pressurized steam cleaning equipment when cleaning the oven.
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. To clean the interior, you have to disassemble some parts of the oven.
SECTION 4 MAINTENANCE 4. Remove conveyor drive chain cover as shown. 5. Remove tension from drive chain by lifting and pushing 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, fold it in half and then place it to the side for cleaning.
SECTION 4 MAINTENANCE B. Air Fingers Disassembly For Cleaning 1. As the air fingers are removed use a felt pen to mark all parts of the fingers. This includes the finger manifold, 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 marked in the order shown; as viewed from the front of the oven. (The marks for an upper oven should be preceded with a “U”, example UB1, UT2, etc.) T1 T2 T3 T4 B1 B2 B3 B4 Standard Fingers 2.
SECTION 4 MAINTENANCE 6. To remove the inner plate, pull the plate out and then up. 1. Remove the window by opening the window and unscrewing the window knobs from each end. Figure 4-15. 2. Push the window all the way inside the oven, making sure it is clear of the frame. Now, turn the window sideways while inside the oven and then remove it. This will avoid breaking the window. Figure 4-12. 7.
SECTION 4 MAINTENANCE 2. Reassemble the inner plate. Keep your fingers clear so 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.
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.
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.
SECTION 4 MAINTENANCE F. Conveyor Reassembly Into Oven G. Checking Conveyor Belt Tension 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 of the oven the drive sprocket assembly must be removed as shown in conveyor disassembly section. Oven conveyor belt must be cool when adjusting belt. Do not adjust belt if HOT. 1.
SECTION 4 MAINTENANCE H. Conveyor Belt Link Removal 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 Figure 4-27. 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.
SECTION 4 MAINTENANCE 6. Reconnect the inside master links (Figure 4-32.) I. Replacing Conveyor Belt 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. Follow the preceding procedure “H. Conveyor belt link removal” which outlines the disassembly procedure. J. Attaching Drive Chain 1.
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 Shut OFF all electrical power and lock/tag out the switch before attempting maintenance work. Shut OFF gas supply to oven. NOTE: It is recommended that the 3-month maintenance be performed by an authorized Middleby Marshall technician. A.
SECTION 4 MAINTENANCE B. Electrical Terminals CAUTION Open the control cabinet door by removing the three screws from the control cabinet door. Tighten all electrical control terminal screws including the electrical contactor terminal screws as shown in Figure 4-39. Overtightening the belt will cause premature bearing failure and possible vibration problems. A spare belt is located inside the control compartment on the rear wall. 3.
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 accelerates grease loss, which shortens bearing life. Wipe off any excess grease on and around the bearing. Reinstall the rear shroud to allow the oven to operate Grease the two (2) main blower fan shaft bearings (Figure 4-43), using a special grease (MM P/N 17110-0015 lithiumbase, high-temperature grease).
SECTION 4 MAINTENANCE 6. Make sure bronze washer is in between the two halves. 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 outlined in Steps 4-6. Figure 4-48. Figure 4-51. 8. Loosen the set screw on each conveyor drive sprocket and remove sprockets. 11.
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. Slide rear conveyor drive sprocket onto shaft. Tighten the set screw of this drive sprocket until it extends into the hole of the hollow shaft. It should NOT touch the inner, solid shaft. Check to see that only the rear shaft moves when the sprocket is turned. If both shafts move, you have tightened the set screw too tight.
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 (Figure 4-56). (The kit can be purchased when the oven is ordered, or later, from a Middleby Marshall Authorized Parts Distributor). The kit contains many of the crucial Replacement parts for this kit can be purchased from your Middleby Marshall Authorized Parts Distributor.
SECTION 5 TROUBLESHOOTING SECTION 5 TROUBLESHOOTING PROBLEM: OVEN BLOWER AND CONVEYOR OPERATE, YET THE OVEN IS NOT HEATING PROBLEM: PRODUCTS ARE OVERCOOKED OR UNDERCOOKED Check for correct setting of conveyor speed control. Check for correct setting on temperature controller. Reset the temperature controller to a new setting (above 200°F), after turning the BLOWER switch to off for 30 seconds. Set the conveyor speed control at correct setting. Turn temperature control to correct setting.
SECTION 5 TROUBLESHOOTING NOTES 48
SECTION 6 PARTS LIST ENGLISH SECTION 6 - PARTS LIST 49
SECTION 6 PARTS LIST ENGLISH 50
A/R A/R 1 1 1 16 8 8 8 4 4 4 20 21 22 23 24 25 26 27 28 29 30 1 13 19 1 12 A/R 1 11 18 1 2 4 9 10 17 1 8 2 2 7 16 1 6 4 16 5 15 8 4 4 21256-0008 8 3 14 33486 2 2 51 45206 45209 45205 21216-0018 21426-0004 21416-0003 21172-0004 22500-0041 22500-0101 22500-0021 21416-0001 21422-0001 220373 22290-0010 22290-0009 37900-0102 37900-0024 54606 42400-0087 30285 37900-0103 50637 49905 21296-0005 45449 36452 49946 49947 2 1 P/N QTY.
SECTION 6 PARTS LIST ENGLISH 52
CONTROL PANEL ENGLISH SECTION 6 PARTS LIST 53
SECTION 6 PARTS LIST ENGLISH 54
BLOWER AND SHROUD ENGLISH SECTION 6 PARTS LIST 55
SECTION 6 PARTS LIST ENGLISH 56
2 4 1 1 1 15 16 17 18 1 9 14 4 8 1 1 7 13 1 6 1 1 5 12 1 4 1 1 3 11 1 2 1 1 1 10 QTY.
SECTION 6 PARTS LIST ENGLISH 58
1 2 4 16 1 1 2 15 16 17 18 19 20 2 9 14 4 8 1 1 7 13 1 6 1 1 5 12 1 4 1 1 3 11 1 2 1 1 1 10 QTY.
SECTION 6 PARTS LIST ENGLISH 60
QTY. 1 1 1 1 1 8 8 8 4 4 4 4 1 1 1 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 61 15 33812-3 31497 36451 A3682 21126-0004 3023A8807 A3896 21416-0001 21422-0001 1513D8805 50449 49953 44687 28021-0061 28021-0047 P/N THERMOCOUPLE, TYPE “J” SHIELDED 9.
SECTION 6 PARTS LIST NOTES ENGLISH 62
SECTION 7 ELECTRICAL SCHEMATICS Wiring Diagram, E208-240 50/60, 3PH 4W PS540ES 50466C SECTION 7 ELECTRICAL SCHEMATICS 63
Wiring Diagram, E380-480 50/60, 3PH 5W PS540ES 50140C SECTION 7 ELECTRICAL SCHEMATICS 64
Wiring Diagram, E380V 50/60, 3PH 5W PS540ES 50467C SECTION 7 ELECTRICAL SCHEMATICS 65
Wiring Diagram, E400-416V 50/60, 3PH 5W PS540ES 51068D SECTION 7 ELECTRICAL SCHEMATICS 66
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.
