Middleby Marshall PS540 (Double) Scheda tecnica

MiddlebyMiddleby

Middleby

MarshallMarshall

Marshall

AMIDDLEBYCOMPANY

PS540-Series Electric Ovens: English

owner's

operating

& installation

manual

PS540-Series

OVENS

Model

PS540E

PS540 (Triple)

PS540 (Double)

Part No. 51415

Price $30.00

P: 10/06

PS540 (Single)

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.

NOTICE

The warranty is

NOT VALID

unless the oven is installed, started, and

demonstrated under the supervision of a factory-authorized installer.

NOTICE

Contact your authorized Service Agency to perform maintenance and

repairs. A Service Agency Directory is supplied with your oven.

NOTICE

Using any parts other than genuine Middleby Marshall factory-manufactured

parts relieves the manufacturer of all warranty and liability.

NOTICE

Middleby Marshall (Manufacturer) reserves the right to

change specifications at any time.

KEEP THIS MANUAL IN A VISIBLE LOCATION NEAR THE OVEN

FOR FUTURE REFERENCE.

iii

MIDDLEBY MARSHALL INC.

OVEN LIMITED WARRANTY

(Non U.S.A.)

The Seller warrants equipment manufactured by it to be free from

defects in material and workmanship for which it is responsible. The

Seller’s obligation under this warranty shall be limited to replacing or

repairing, at Seller’s option, without charge, F.O.B. Seller’s factory,

any part found to be defective and any labor and material expense

incurred by Seller in repairing or replacing such part. Such warranty

is limited to a period of one year from date of original installation or

15 months from date of shipment from Seller’s factory, whichever is

earlier, provided that terms of payment have been fully met. All labor

shall be performed during regular working hours. Overtime premium

will be charged to the Buyer.

This warranty is not valid unless equipment is installed, 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.

Any repairs or replacements of defective parts shall be performed by

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.

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

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

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 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 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.

The foregoing shall be Seller’s sole and exclusive obligation and

Buyer’s sole and exclusive remedy for any action, whether in breach

of contract or negligence. In no event shall seller be liable for a sum

in excess of the purchase price of the item.

Model No.

Modéle No.

Serial No.

Serié No.

Installation Date

Date d'installation

MIDDLEBY MARSHALL

NOQUIBBLE LIMITED WARRANTY

(U.S.A. ONLY)

MIDDLEBY MARSHALL, HEREINAFTER REFERRED TO 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 UNDER THIS WARRANTY SHALL

BE LIMITED TO 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, PROVIDED THATTERMS

OF PAYMENT HAVE BEEN FULLY MET.

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

and demonstrated under the supervision of a factory-autho-

rized installer.

Normal maintenance functions, including lubrication, clean-

ing, or customer abuse, are not covered by this

no quibble

warranty

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.

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 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.

This warranty is effective on Middleby Marshall equip-

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

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

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

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 .............................................. 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. Electric Heaters ........................................................ 6

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

E. Cooling Fan ................................................................ 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 ELECTRIC OVEN

INSTALLATION KIT .................................................. 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

CIRCUIT BREAKER ..................................................... 17

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

ELECTRICAL RATING ................................................. 17

SUPPLY WIRE .............................................................. 17

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

II. VENTILATION GUIDELINES ....................................... 18

VENTILATION HOOD ................................................... 18

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

III. ELECTRICAL CONNECTION INFORMATION FOR

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

IV. ELECTRIC SUPPLY FOR ELECTRIC-HEATED

OVENS ....................................................................... 19

VI. CONVEYOR REAR STOP AND

END STOP INSTALLATION ...................................... 20

SECTION 3 INSTALLATION

I. CONTROL FUNCTIONS ................................................ 21

II. COMPONENT INFORMATION AND LOCATION ......... 22

A. Door Safety Switch .................................................. 22

B. Blower Switch .......................................................... 22

C. Heat Switch .............................................................. 22

D. Temperature Controller .......................................... 22

E. Conveyor ................................................................. 23

MEASURING CONVEYOR SPEED. ............................. 23

III. STEP-BY-STEP OPERATION ..................................... 24

A. Startup Procedures ................................................. 24

TABLE OF CONTENTS

(Continued)

Page

Daily Startup ................................................................. 24

Power Failure ............................................................... 24

B. Shutdown Procedure ............................................... 24

A.Daily Startup Procedure .......................................... 26

IV. NORMAL OPERATION - STEP-BY-STEP .................. 26

V. QUICK REFERENCE: TROUBLESHOOTING ............. 28

SECTION 4 MAINTENANCE

I. MAINTENANCE - DAILY ........................................... 30

A. Exterior .................................................................... 30

B. Cooling Fan .............................................................. 30

C. Conveyor Belt ......................................................... 30

D. Crumb Pans ............................................................ 30

E. Window .................................................................... 30

II. MAINTENANCE - MONTHLY ...................................... 31

A. Removing Conveyor From Oven For Cleaning .... 31

B. Air Fingers Disassembly For Cleaning ................. 33

C. Cleaning the Window .............................................. 34

D. Reassembly of Air Fingers .................................... 34

E. Reinstall End Plugs ................................................. 37

F. Conveyor Reassembly Into Oven .......................... 38

G. Checking Conveyor Belt Tension ......................... 38

H. Conveyor Belt Link Removal ................................ 39

I. Replacing Conveyor Belt ......................................... 40

J. Attaching Drive Chain ............................................ 40

III. MAINTENANCE - EVERY 3 MONTHS ........................ 41

A. Cleaning the Blower/Fan Motor ............................. 41

B. Electrical Terminals ............................................... 42

C. Ventilation ............................................................... 42

D. Checking the Blower/Fan Belt ............................... 42

E. Blower Fan Shaft Bearing Lubrication .................. 43

F. Split-belt Conveyor Shaft Cleaning ........................ 43

IV. MAINTENANCE - EVERY 6 MONTHS .................... 44

PS540-SERIES ELECTRIC OVEN KEY SPARE

PARTS ....................................................................... 46

KEY SPARE PARTS KIT .............................................. 46

SECTION 5 TROUBLESHOOTING

Troubleshooting Charts ..................................................... 47

SECTION 6 - PARTS LIST

OVEN PANELS, WINDOW AND LEGS ............................ 51

CONTROL PANEL ........................................................... 53

BLOWER AND SHROUD ................................................. 55

CONVEYOR ...................................................................... 57

SPLIT BELT CONVEYOR ................................................. 59

MACHINERY COMPARTMENT ....................................... 61

SECTION 7 ELECTRICAL SCHEMATICS

Wiring Diagram, E208-240 50/60, 3PH 4W PS540 ........ 63

Wiring Diagram, E380-480 50/60, 3PH 5W PS540 ........ 64

Wiring Diagram, E380V 50/60, 3PH 5W PS540 .............. 65

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. 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. All ovens use identical controls and compo-

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

others are operating.

SECTION 1

DESCRIPTION

Figure 1-1. Single PS540 Oven

Figure 1-2. Double PS540 Oven

Figure 1-3. Triple PS540 Oven

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.)

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 925 lb (419kg)

Shipping Weight 1,100 lb (498.3kg)

Shipping Cube Approx. 132 ft3(3.74 m3)

Operating Range 27 kW/hr)

Maximum Operating Temperature 550°F (287°C)

Warm-up Time 15 min.

Recirculating Air Fan One fan at 2300 RPM

Air Velocity 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 & Control Circuit Phase Frequency Amperage Poles Wires

Elements Voltage Voltage Draw

208-240V 208-240V 3 Ph 50/60 Hz 100 Amp 4 Pole 4 Wire

(3 hot, 1 grd)

HEATER AMPERAGE

Voltage kW Amp

208 27 75

240 27 65

380-400V 208-240V 3 Ph 50/60 Hz 50 Amp 4 Pole 5 Wire

(3 hot, 1neut, 1 grd)

HEATER AMPERAGE

Voltage kW Amp

380-400 27-29.9 40-44

400V 208-240V 3 Ph 50/60 Hz 50 Amp 4 Pole 5 Wire

(3 hot, 1neut, 1 grd)

HEATER AMPERAGE

Voltage kW Amp

400 27 32.5

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

Average Amps

37 37 37

33 33 33

Average Amps

22 22 22

Average Amps

28 28 28

SECTION 1

DESCRIPTION

II. PRINCIPLE OF AIR FLOW

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. Air is then pulled back into the blower

and the process continues. The curving, black arrows of

Figure 1-4 show this air flow.

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.

Conduction:

This path utilizes surface-to-surface con-

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

example of conduction.

Radiation:

This path has to do with objects radiating heat.

Dark objects absorb heat whereas light or shiny objects

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.

Convection:

This path has to do with moving a volume of

air. It explains why hot air rises and cooler air replaces hot

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.

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

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

tion, radiation and convection. The speed at which the heat

flows is determined by the temperature difference between

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

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

Upper Air Fingers

Lower Air Fingers

Conveyor Belt(s)

Window

Figure 1-4. PS540-Series Oven Air Flow

SECTION 1

DESCRIPTION

Series ovens used to bake pizza have four bottom fingers

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.

NOTE:

Some customers have a predetermined finger

arrangement. If you have any questions pertaining to the

finger arrangement, please call the factory.

Air Flow

From Plenum

Manifold

Manifold Baffle

Outer Plate

Inner Plate

Air Flow

From Plenum

Manifold

Manifold Baffle

Outer Plate

Inner Plate

High Velocity

Columns of Air

on Food Product

II. PRINCIPLE OF AIR FLOW (Continued)

B. Air Fingers

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

streams of hot air provide an exceptional heat transfer rate

and generally bake faster and at lower temperatures than

convection hot air or infrared heating ovens.

A PS540-Series Oven can accommodate up to four

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

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.

SECTION 1

DESCRIPTION

III. COMPONENT FUNCTION (Figure 1-6)

Figure 1-6. PS540-Series Oven Components Locations

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 stain-

less-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. This

blower forces heated air through the air fingers. The

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

warmup and baking.

C. Electric Heaters

There is one heater element mounted on the inside of the

rear panel. The element is connected to an electrical

control which is energized by the temperature controller.

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

A window on the front of the oven permits viewing the items

being baked and provides access to the oven for items that

do not require full baking time, such as sandwiches,

cookies, small items, or cheese-melting processes.

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

compartment into the oven top and exhausted out the front

louvers.

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

F1. Air Fingers

An Air Finger Assembly is made up of three parts:

1. Outer Plate - The Outer Plate is the removable covering

with tapered holes, which direct the air stream onto the

product being baked.

2. Inner Plate -The perforated Inner Plate is vital in forming

the unique air jets. It must be assembled into the manifold

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.

Figure 1-7. Machinery Compartment

Components

Left Control Box

Right Control Box

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