Page 2 - ii; FOR YOUR SAFETY, DO NOT STORE OR USE; WARNING; The warranty is; unless; repairs. A Ser vice Agency Directory is supplied with your oven.
ii WARNING FOR YOUR SAFETY, DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS ANDLIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. WARNING POST, IN A PROMINENT LOCATION, THE EMERGENCY PHONENUMBER OF YOUR LOCAL GAS SUPPLIER AND INSTRUCTIONSTO BE FOLLOWED IN THE EVENT YOU SMELL GAS. INSTRUC...
Page 3 - iii; MIDDLEBY MARSHALL INC.; UIBBLE; NLY
iii MIDDLEBY MARSHALL INC. OVEN LIMITED WARRANTY (Non U.S.A.) The Seller warrants equipment manufactured by it to be free fromdefects in material and workmanship for which it is responsible. TheSeller’s obligation under this warranty shall be limited to replacing orrepairing, at Seller’s option, wit...
Page 4 - iv; NOTE; Wiring Diagrams are in Section 7 of this Manual.; TABLE OF CONTENTS
iv 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. TABLE OF CONTENTS Page SECTION 1 I. MODEL IDENTIFICATION .............................................. 1SERIES PS540 ELECTRICAL SPECIFICATIONS ............. ...
Page 5 - MODEL IDENTIFICATION; The major difference between the oven models in; SECTION 1
SECTION 1 DESCRIPTION 1 I. MODEL IDENTIFICATION The Middleby Marshall PS540-Series may be used eitheras a single oven or stacked for use as double or tripleovens. 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 moun...
Page 6 - Wiring Diagrams are contained in Section 7 of this Manual; This Manual Must Be Kept For Future Reference
2 SECTION 1DESCRIPTION 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.) Overall Dimension Standard Single Oven w/Legs 80 ″ (2032mm) L × 61-5/16 ″ (1557mm) W × 47-5/16 ″ (1202mm) H × Overall Dimensi...
Page 7 - II. PRINCIPLE OF AIR FLOW; A. Heat Transfer and How It Works; This path has to do with objects radiating heat.
SECTION 1 DESCRIPTION 3 II. PRINCIPLE OF AIR FLOW The fan-style blower draws air into the oven plenum whereit is heated. The blower then pushes the hot air through theair fingers into the baking chamber. Each air fingercontains an inner plate and outer plate that form the hot airinto jets, distribut...
Page 8 - Some customers have a predetermined finger; the Inner Plate and Outer Plate to Heat the Food Product.
4 SECTION 1DESCRIPTION Series ovens used to bake pizza have four bottom fingersand two top fingers. For special product baking require-ments, a number of other styles of fingers and fingerarrangements are available from the factory. NOTE: Some customers have a predetermined finger arrangement. If yo...
Page 10 - III. COMPONENT FUNCTION; A. Conveyor Motor and Conveyor Belt; Figure 1-7. Machinery Compartment Components; Left Control Box; only after
6 SECTION 1DESCRIPTION III. COMPONENT FUNCTION A. Conveyor Motor and Conveyor Belt The conveyor belt is driven by a variable-speed electricmotor (Figure 1-7) operating through a gear reducer. Themotor speed is controlled by a digital control. The stain-less-steel wire belt can travel in either direc...
Page 11 - Cooling Fan Grille
SECTION 1 DESCRIPTION 7 Figure 1-8. Cooling Fan Cooling Fan Grille 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 itthrough the blower motor compartment and the controlcompartment into the oven top and exha...
Page 12 - Inner Plate
8 SECTION 1DESCRIPTION Half Blank Plate Blank Plate Outer Plate Inner Plate Finger Manifold Assembly Baffle Figure 1-9. Blank Plates (two sizes) and an Air Finger. F2. Blank Plates 1. Blank Plates- The Blank Plates are available to install on the plenum where an air finger is not required. F. Air Fi...
Page 13 - SECTION 2; CAUTION
SECTION 2 INSTALLATION 9 SECTION 2 INSTALLATION NOTE: In U.S.A., the oven installation must conform with local codes, or in the absence of local codes, with theNational Fuel Gas Code, ANSI Z223.1 latest edition. Theoven, when installed, must be electrically grounded inaccordance with local codes, or...
Page 14 - Installation Parts
10 SECTION 2INSTALLATION PS540 OVEN INSTALLATION REQUIRED KITS AND EQUIPMENT TYPE PS540 PS540 Single PS540 Double PS540 Double PS540 Triple OF Gas Oven Oven Option Oven Option Oven Option Oven Option INSTALLATION Installation Base w/15 ″ Legs, Base w/6 ″ Legs, Base w/Casters Base w/Casters Kit P/N C...
Page 15 - PARTS LIST FOR PS540 SERIES SINGLE OVEN OPTION - BASE w/15; ITEM; Option Base with Legs and Top
SECTION 2 INSTALLATION 11 PARTS LIST FOR PS540 SERIES SINGLE OVEN OPTION - BASE w/15 ″″″″″ LEGS & TOP P/N 34832 ITEM NO. QTY PART NO. DESCRIPTION 1 1 37900-0025 COMPLETE BASE WELDMENT 2 4 37900-0024 TOP PLATE, LEG WELDMENT 3 2 22290-0009 SWIVEL CASTER W/BRAKE FLAT PLATE 4 2 22290-0010 SWIVEL CAS...
Page 16 - PARTS LIST FOR PS540 SERIES DOUBLE OVEN OPTION - BASE w/6
12 SECTION 2INSTALLATION PARTS LIST FOR PS540 SERIES DOUBLE OVEN OPTION - BASE w/6 ″″″″″ LEGS, CASTERS & TOP P/N 34833 ITEM NO. QTY PART NO. DESCRIPTION 1 1 37900-0025 COMPLETE BASE WELDMENT 2 4 37900-0102 TOP PLATE, LEG WELDMENT 3 2 22290-0009 SWIVEL CASTER W/BRAKE FLAT PLATE 4 2 22290-0010 SWI...
Page 17 - PARTS LIST FOR PS540 SERIES TRIPLE OVEN OPTION - BASE w/CASTERS & TOP; Option Base with Outriggers and Top
SECTION 2 INSTALLATION 13 PARTS LIST FOR PS540 SERIES TRIPLE OVEN OPTION - BASE w/CASTERS & TOP P/N 51139 ITEM NO. QTY PART NO. DESCRIPTION 1 1 54606 COMPLETE BASE WELDMENT 2 4 45209 QUAD OUTRIGGER WELDMENT 3 2 22290-0009 SWIVEL CASTER, W/BRAKE FLAT PLATE 4 2 22290-0010 SWIVEL CASTER, FLAT PLATE...
Page 18 - Figure 2-5. MODEL PS540 SINGLE OVEN DIMENSIONS; GAS INLET
14 SECTION 2INSTALLATION Figure 2-5. MODEL PS540 SINGLE 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 ″ 1 2 3 2 3 3 3 1
Page 19 - Figure 2-6. MODEL PS540 DOUBLE OVEN DIMENSIONS
SECTION 2 INSTALLATION 15 Figure 2-6. MODEL PS540 DOUBLE 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 ″ 1 2 3 2 3 3 3 1
Page 20 - RESTRAINT CABLE INSTALLATION; Figure 2-7. MODEL TRIPLE OVEN DIMENSIONS; Figure 2-8. Restraint Cable Assembly Installation
16 SECTION 2INSTALLATION RESTRAINT CABLE INSTALLATION Install the restraint cable assembly on the oven, as shownin Figure 2-6. 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 ...
Page 21 - Installation
SECTION 2 INSTALLATION 17 WARNING DO NOT USE CONDUIT OR GAS LINEFOR GROUND CONNECTION. CAUTION IT IS REQUIRED THAT THE OVEN BEP L A C E D U N D E R A V E N T I L A T I O NHOOD FOR ADEQUATE AIR SUPPLYAND VENTILATION. ELECTRIC AND GAS SUPPLY TO BE PROVIDED BY CUSTOMER ELECTRICAL SAFETY SWITCH 15 Amp c...
Page 22 - Return air from fan driven system within the hood; VENTILATION CAPTURE TEST
18 SECTION 2INSTALLATION II. VENTILATION GUIDELINES A mechanically driven ventilation system is required forthe PS540 Series Middleby Marshall conveyorized gasovens. The minimum hood canopy dimensions are out-lined below. Local codes and conditions vary greatly from one area toanother and must be co...
Page 23 - The electric supply installation must satisfy the; Do NOT use the
SECTION 2 INSTALLATION 19 III. ELECTRICAL CONNECTION INFORMATION FOR PS540-SERIESOVENS. WARNING Authorized supplier personnel normally accom-plish the connections for the ventilation system,electric supply, and gas supply, as arranged bythe customer. Following these connections, thefactory-authorize...
Page 24 - and its individual shutoff valve; be disconnected from the gas supply; MUST; be isolated from the gas; MUST; MUST; be opened; very; After initial turn-on of gas, the individual
20 SECTION 2INSTALLATION V. GAS SUPPLY FOR GAS HEATED OVENS WARNING During gas line pressure testing, observe thefollowing precautions: 1. The oven and its individual shutoff valve MUST be disconnected from the gas supply piping system during any pressure testing ofthat system at test pressures in e...
Page 25 - Gas Conversion; The terms of the oven’s warranty require all start-; PS540 Propane Conversion; Two items have to be changed, to change the oven to LP:; Adjusting the Maximum Pressure Setting; Figure 2-13. Flexible Gas Hose Installation
SECTION 2 INSTALLATION 21 A. Connection Check the oven’s gas supply requirements before making thegas utility connection. Gas supply requirement are listed onthe oven’s serial plate and in Table 1-4. Gas Orifice andPressure Specifications (in Section 1, Description). Check the serial plate to determ...
Page 26 - Adjusting the Minimum Pressure Setting; Checkout; VI. CONVEYOR REAR STOP AND END; Figure 2-17. Installing Rear and End Stops
22 SECTION 2INSTALLATION E. Adjusting the Minimum Pressure Setting 1. Disconnect pressure feedback connection (if appcable). 2. Connect a suitable pressure gauge to pipe line or to outletpressure tap of gas control concerned, to measure burnerpressure (measuring point must be as near to burner aspos...
Page 27 - SECTION 3
SECTION 3 OPERATION 23 SECTION 3 OPERATION I. CONTROL FUNCTIONS WARNING The burner cannot operate and gas cannot flowthrough the burner without electric power. DoNOT attempt to operate the oven during a poweroutage. WARNING A possibility of injury from rotating parts andelectric shock exists in this...
Page 28 - II. COMPONENT INFORMATION AND; A. Door Safety Switch; D. Temperature Controller
24 SECTION 3OPERATION II. COMPONENT INFORMATION AND LOCATION (Figures 3-1 and 3-2) A. Door Safety Switch The Door Safety Switch is located at the lower left side ofcontrol panel opening. Opening the control panel doorpermits this switch to open, disconnecting power to allelectrical controls. CAUTION...
Page 29 - MEASURING CONVEYOR SPEED.; conveyor running right to left.; Figure 3-3. Conveyor Speed Digital Control
SECTION 3 OPERATION 25 E. Conveyor The on-off switch for the conveyor motor is on the controlpanel. Also on the control panel is the digital conveyorspeed control. The digital control can be adjusted from 3min. to 30 min. bake time (conveyor speed). Refer toFigure 3-3. Conveyor speed is measured by ...
Page 32 - A.Daily Startup Procedure; DAILY SHUTDOWN PROCEDURE; or
28 SECTION 3OPERATION CAUTION In case of power failure, turn all switches to the “OFF”("O") position, open the oven window, and removethe product. After the power has been restored,perform the normal startup procedure. IF THE OVENWAS SWITCHED OFF FOR LESS THAN 5 MINUTES,WAIT FOR AT LEAST FIV...
Page 33 - Service use
SECTION 3 OPERATION 29 Display Shows the Set Point or the Actual Tem- perature in degrees Fahrenheit (F) or Celsius (C). "SP LOCK" Light Lights when the set point is lockedout from changes. This setting can only be changed by service personnel. OVERTEMP Light Lights when the oven temperature...
Page 35 - SECTION 4; NOTICE
SECTION 4 MAINTENANCE 31 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...
Page 36 - IMPORTANT NOTE; The window can be cleaned daily while it is in place.; Crumb Pan Cleaning
32 SECTION 4MAINTENANCE I. MAINTENANCE - DAILY A. Exterior Everyday you should clean the outside of the oven with asoft cloth and mild detergent. WARNING Never use a water hose or pressurized steamcleaning equipment when cleaning the oven. B. Cooling Fan 1. TWO COOLING FAN GRILLES AT THE REAR OFEACH...
Page 37 - PRECAUTIONS
SECTION 4 MAINTENANCE 33 Figure 4-3. II. MAINTENANCE - MONTHLY When cleaning your Series PS540 Oven note thefollowing: PRECAUTIONS - 1. Do not use excessive water or saturation of oveninsulation will occur. 2. Do not use a caustic oven cleaner or the aluminizedfinger manifold surfaces will be severe...
Page 39 - B. Air Fingers Disassembly For Cleaning; Standard Fingers; Some oven users require a custom finger arrange-
SECTION 4 MAINTENANCE 35 B. Air Fingers Disassembly For Cleaning 1. As the air fingers are removed use a felt pen to mark allparts of the fingers. This includes the finger manifold, innerplate and the outer plate (refer to Figure 1-9). If a blank orchoke plate is used, mark that plate also. Fingers ...
Page 40 - To remove the inner plate, pull the plate out and then up.; C. Cleaning the Window
36 SECTION 4MAINTENANCE 6. To remove the inner plate, pull the plate out and then up. Figure 4-12. 7. The outer finger plate is stainless and may be cleanedby either soaking in a hot, strong detergent solution orusing a caustic cleaner. The conveyor belt can also becleaned in the same way. Figure 4-...
Page 41 - Only M6 Fingers fit in the bottom
SECTION 4 MAINTENANCE 37 2. Reassemble the inner plate. Keep your fingers clear soyou won’t pinch them. The inner plate of a finger will onlygo in one way because of its design. 3. Replace the outer plate by placing your hands flat onthe top of the plate and pushing down. Keep your fingersclear so y...
Page 43 - E. Reinstall End Plugs; Reinstall upper end plug. Be sure to tighten two wing
SECTION 4 MAINTENANCE 39 E. Reinstall End Plugs 1. Reinstall lower end plug. Be sure to tighten two wingscrews 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.
Page 44 - G. Checking Conveyor Belt Tension; F. Conveyor Reassembly Into Oven; Lift conveyor and position it in oven as shown.
40 SECTION 4MAINTENANCE G. Checking Conveyor Belt Tension WARNING Oven conveyor belt must be cool when adjustingbelt. Do not adjust belt if HOT. 1. With the conveyor assembly in the oven, stand at oneend of conveyor and check tension by lifting the conveyorbelt at the center of the oven chamber open...
Page 45 - H. Conveyor Belt Link Removal; If a section of the conveyor belt is being replaced
SECTION 4 MAINTENANCE 41 H. Conveyor Belt Link Removal 1. Using long nose pliers, an entire link can be removedwith the conveyor assembly either in or out of the oven.Position master links at end of conveyor as shown inFigure 4-27. Figure 4-27. 2. Using long nose pliers, unhook master links at left ...
Page 47 - Install both upper end plugs.; Shut OFF gas supply to oven.; Cleaning the Blower/Fan Motor
SECTION 4 MAINTENANCE 43 4. Reassemble conveyor drive chain cover and thenreassemble the bottom cover to the drive chain cover. Install both upper end plugs. Figure 4-37. Conveyor D.C. Motor Bur ner• Blower• Motor Fan Motor- • Blow Out• In This Area III. MAINTENANCE - EVERY 3 MONTHS WARNING Shut OFF...
Page 48 - B. Electrical Terminals; The fan belt should deflect no less than 1
44 SECTION 4MAINTENANCE B. Electrical Terminals Open the control cabinet door by removing the threescrews from the control cabinet door. Tighten all electricalcontrol terminal screws including the electrical contactorterminal screws as shown in Figure 4-39. Figure 4-39. C. Ventilation Check that the...
Page 49 - E. Blower Fan Shaft Bearing Lubrication
SECTION 4 MAINTENANCE 45 E. Blower Fan Shaft Bearing Lubrication CAUTION Over-greasing damages the bearing seals andaccelerates grease loss, which shortens bearinglife. Wipe off any excess grease on and aroundthe bearing. Reinstall the rear shroud to allow theoven to operate Grease the two (2) main ...
Page 50 - Make sure bronze washer is in between the two halves.
46 SECTION 4MAINTENANCE 6. Make sure bronze washer is in between the two halves. Figure 4-47. 7. Place the idler shaft assembly back into place andreinstall the adjustment screws. Figure 4-48. 8. Loosen the set screw on each conveyor drive sprocketand remove sprockets. Figure 4-49. 9. Loosen the spl...
Page 51 - should NOT
SECTION 4 MAINTENANCE 47 12. Slide shaft assembly to right side, holding assemblyin place. Slide split locking collar to the left side andtighten. 13. Slide rear conveyor drive sprocket onto shaft. Tightenthe set screw of this drive sprocket until it extends into thehole of the hollow shaft. It shou...
Page 52 - KEY SPARE PARTS KIT
48 SECTION 4MAINTENANCE PS540-SERIES GAS OVEN KEY SPARE PARTS (Figure 4-56) ITEM PART NO. ENGLISH DESCRIPTION QUANTITY 1 47321 Temperature Controller 1 2 44687 Blower/Fan Motor 1 3 47797 Conveyor Drive Motor 1 4 60542 Conveyor Speed Control 1 5 33812-3 Thermocouple 1 6 60679 Assy, Valve Gas Module 1...
Page 53 - SECTION 5
49 SECTION 5 TROUBLESHOOTING SECTION 5 TROUBLESHOOTING PROBLEM: PRODUCTS ARE OVERCOOKED OR UNDERCOOKED Check for correct setting of conveyor speed control. Set the conveyor speed control at correct setting. Check for correct setting on tempera- ture controller. Turn temperature control to correct se...
Page 54 - NOTES
Page 55 - ENGLISH; SECTION 6; SECTION 6 - PARTS LIST
51 ENGLISH SECTION 6 PARTS LIST SECTION 6 - PARTS LIST
Page 71 - SECTION 7
67 SECTION 7 ELECTRICAL SCHEMATICS SECTION 7 ELECTRICAL SCHEMATICS Wiring Diagram, G208-240 50/60, 1PH 3W PS540 50141H
Page 76 - can cause property damage, injury or death. Read the installation,; the manufacturer of all warranty and liability.
Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • USA • (847)741-3300 • FAX (847)741-4406 24-Hour Service Hotline: 1-(800)-238-8444 www.middleby.com Middleby is proud to support the Commercial Food EquipmentService Association (CFESA). We recognize and applaudCFESA's ongoin...
