Middleby Marshall PS640G Installation manual

PS640 Series
Electric
Domestic & Std. Export
ENGLISH
P/N 60614
October 2007
PS640 Series Electric Ovens
Model:
Combinations:
•
•
•
•
PS640E Electric
Single Oven
Double Oven (Two-Stack)
Triple Oven (Three-Stack)
OWNER'S OPERATING AND
INSTALLATION MANUAL
for domestic and standard export ovens
©2007 Middleby Marshall Inc.
is a registered trademark of Middleby Marshall, Inc. All rights reserved.
Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • (847)741-3300 • FAX (847)741-4406
NOTICE:
This Owner's Operating and Installation Manual should be given to the user. The operator of the oven should be
familiar with the functions and operation of the oven.
This manual must be kept in a prominent, easily reachable location near the oven.
It is suggested to obtain a service contract with a Middleby Marshall Authorized Service Agent.
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.
IMPORTANT
An electrical wiring diagram for the oven is located inside the machinery compartment.
IMPORTANT
It is the customer’s responsibility to report any concealed or non-concealed damage to the
freight company. Retain all shipping materials until it is certain that the equipment has
not suffered concealed shipping damage.
NOTICE
CONTACT YOUR MIDDLEBY MARSHALL AUTHORIZED SERVICE AGENT TO PERFORM
MAINENANCE AND REPAIRS. AN AUTHORIZED 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.
NOTICE
The equipment warranty is not valid unless the oven is installed, started and demonstrated under the
supervision of a factory certified installer.
NOTICE
A Middleby Marshall certified installer must be used to install and service this appliance.
NOTICE
This equipment is only for professional use and shall be used by qualified people.
RETAIN THIS MANUAL FOR FUTURE REFERENCE.
Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 USA • (847)741-3300 • FAX (847) 741-4406
www.middleby.com
ii
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. 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.
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 EFFECTIVE FOR A PERIOD OF
ONE YEAR FROM DATE OF ORIGINAL INSTALLATION, OR
18 MONTHS FROM DATE OF PURCHASE, WHICHEVER
IS EARLIER, PROVIDED THAT TERMS OF PAYMENT HAVE
BEEN FULLY MET.
This warranty is not valid unless equipment is installed, started,
and demonstrated under the supervision of a factory-authorized installer.
Normal maintenance functions, including lubrication, adjustment of
airflow, thermostats, door mechanisms, microswitches, burners and
pilot burners, and replacement of light bulbs, fuses and indicating
lights, are not covered by warranty.
This warranty is valid only if the equipment is installed, started,
and demonstrated under the supervision of a factory-authorized installer.
Any repairs or replacements of defective parts shall be performed by
Seller’s authorized service personnel. Seller shall not be responsible for any costs incurred if the work is performed by other than
Seller’s authorized service personnel.
Normal maintenance functions, including lubrication, cleaning, 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 principal 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 particular 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, including 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 WHATSOEVER. SPECIFICALLY THERE ARE NO IMPLIED WARRANTIES
OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE.
This warranty is effective on Middleby Marshall equipment sold on, or after, February 15, 1995.
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.
© 2003 - Middleby Marshall, A Middleby Company.
The Middleby Marshall logo is a registered trademark of Middleby Marshall, A Middleby Company.
Middleby Marshall Inc. • 1400 Toastmaster Drive • Elgin, Illinois 60120-9272 U.S.A. • (847) 741-3300 • FAX: (847) 741 4406
iii
TABLE OF CONTENTS
Page
Page
SECTION 3 – OPERATION .............................................. 15
I. LOCATION AND DESCRIPTION OF CONTROLS 15
II. NORMAL OPERATION, STEP-BY-STEP ................ 16
A. Main Screen ................................................ 16
B. Daily Startup Procedure .............................. 17
C. Daily Shutdown Procedure ......................... 17
III. QUICK REFERENCE: TROUBLESHOOTING ...... 18
IV. SCREEN ALERTS ................................................. 18
SECTION 1 – DESCRIPTION ............................................ 1
I. OVEN USES ............................................................ 1
II. OVEN COMPONENTS ............................................ 1
A. Conveyor Motor Drive ................................... 1
B. Crumb Pans .................................................. 1
C. Conveyor ....................................................... 1
D. End Plugs ...................................................... 1
E. Eyebrows ...................................................... 1
F. Window ......................................................... 1
G. Machinery Compartment Access Panel ........ 1
H. Serial Plate .................................................... 1
I. Control Panel ................................................ 1
J. Photo Cell ..................................................... 1
K. Blowers ......................................................... 1
L. Air Fingers ..................................................... 1
III. OVEN SPECIFICATIONS ........................................ 2
A. Dimensions ................................................... 2
B. General Specifications .................................. 2
C. Gas Orifice and Pressure Specifications
for PS640 Electric Ovens .............................. 2
SECTION 4 – MAINTENANCE ........................................ 19
I. MAINTENANCE – DAILY ....................................... 19
II. MAINTENANCE – MONTHLY ............................... 20
III. MAINTENANCE – EVERY 3 MONTHS ................. 21
IV. MAINTENANCE – EVERY 6 MONTHS ................ 22
V. KEY SPARE PARTS KIT ....................................... 23
SECTION 5 – TROUBLESHOOTING .............................. 24
SECTION 6 – ELECTRICAL WIRING DIAGRAM ............ 25
WIRING DIAGRAM, 640 Electric Oven, E208/240V,
50/60 Hz, 3 Ph .............................................................. 25
WIRING DIAGRAM, 640 Electric Oven, E380-480V,
50/60 Hz, 3 Ph .............................................................. 26
SECTION 2 – INSTALLATION ........................................... 3
I. BASE PAD KIT ......................................................... 4
II. INSTALLATION KIT ................................................. 5
III. VENTILATION SYSTEM .......................................... 8
A. Requirements ................................................ 8
B. Recommendations ........................................ 8
C. Other Ventilation Concerns ........................... 8
IV. ASSEMBLY .............................................................. 9
A. Base Pad, Legs, Casters .............................. 9
B. Stacking ....................................................... 10
C. Restraint Cable Installation ......................... 10
D. Conveyor Installation .................................. 11
E. Standoff Installation .................................... 11
V. FINAL ASSEMBLY ................................................. 12
VI. ELECTRICAL SUPPLY .......................................... 13
Connection ....................................................... 13
UTILITY ROUGH-IN DIMENSIONS AND
POSITIONING FOR PS840-SERIES OVENS ....... 14
Circuit Breaker ................................................. 14
Electrical Specifications ................................... 14
Electrical Rating ............................................... 14
Supply Wire ...................................................... 14
Suggested ........................................................ 14
NOTE
Wiring Diagrams are in Section 6 of this Manual.
The diagram for each oven is also on the lower
inner surface of its Control Console.
iv
SECTION 1 – DESCRIPTION
Figure 1-1. Oven Components
I. OVEN USES
PS640 Series Ovens can be used to bake and/or cook a wide
variety of food products, such as pizza, pizza –type products,
cookies, sandwiches and others.
E
D
J
I
II. OVEN COMPONENTS – see Figure 1-1.
A.
Conveyor Drive Motor: Moves the conveyor.
B.
Crumb Pans: Catch crumbs and other materials that drop
through the conveyor belt. One crumb pan is located at
each end of the conveyor.
C.
Conveyor: Moves the food product through the oven.
D.
End Plugs: Allow access to the oven’s interior.
E.
Eyebrows: Can be adjusted to various heights to prevent
heat loss into the environment.
F.
Window: Allows the user to access food products inside
the baking chamber.
F
H
A
C
B
G. Machinery Compartment Access Panel: Allows access
to the oven’s interior and control components. No user
serviceable parts are located in the machinery compartment.
H.
Serial Plate: Provides specifications for the oven that
affect installation and operation. Refer to Section 2, Installation for details.
I.
Control Panel: Location of the operating controls for the
oven. Refer to Section 3, Operation, for details.
J.
Photo Cell: Turns oven On when beam is interrupted.
Not Shown:
K.
Blowers: Project hot air from the burner or heating element
to the air fingers.
L.
Air Fingers: Project streams of hot air onto the food
product.
G
1
I. OVEN SPECIFICATIONS
Single Oven
Table 1-1 Dimensions
Double Oven
Triple Oven
Overall Height
48-3/16″ (1219mm)
62-3/4″ (1575mm)
78-11/16″ (1981mm)
Overall Depth
60″ (1524mm)
60″ (1524mm)
60″ (1524mm)
Overall Length
76-1/2″ (1930mm)
76-1/2″ (1930mm)
76-1/2″ (1930mm)
Conveyor Width – belt width is 32″
33-1/2″ (838mm)
or 2 × 15″ (381mm)
33-1/2″ (838mm)
or 2 × 15″ (381mm)
33-1/2″ (838mm)
or 2 × 15″ (381mm)
Rear of Oven to Wall
3″ (76mm)
3″ (76mm)
3″ (76mm)
Control end of conveyor to Wall
1″ (25.4mm)
1″ (25.4mm)
1″ (25.4mm)
Non-control end of conveyor to Wall)
1″ (25.4mm)
1″ (25.4mm)
1″ (25.4mm)
Recommended Minimum Clearances
Table 1-2: General Specifications
PS640 ELECTRIC
Weight
1150 lbs. (522kg)
Rated Heat Input
34.4 kW/hr (117,500 BTU, 29,610 kcal)
Maximum Operation Temperature
600°F / 315°C
Air Blowers
Two Blowers at 1900 RPM
Warmup Time
15 min.
SERIES PS640 ELECTRICAL SPECIFICATIONS
Main Blower &
Elements Voltage
Control Circuit
Voltage
Phase
Frequency
Amperage
Draw
Poles
Wires
208-240V
208-240V
3 Ph
50/60 Hz
100 Amp
4 Pole
4 Wire
(3 hot, 1 grd)
HEATER AMPERAGE
Voltage
208
240
380V
208-240V
Voltage
380v
480V
208-240V
Voltage
480
kW
34.4
34.4
Amp
75
65
37
33
3 Ph
kW
34.4
50/60 Hz
HEATER AMPERAGE
Amp
Average Amps
40-44
22
22
3 Ph
kW
34.4
Average Amps
37
33
50/60 Hz
HEATER AMPERAGE
Amp
Average Amps
32.5
28
28
37
33
50 Amp
4 Pole
5 Wire
(3 hot, 1neut, 1 grd)
4 Pole
5 Wire
(3 hot, 1neut, 1 grd)
22
60 Amp
28
IMPORTANT – Additional electrical information is provided on the oven’s serial plate, and on the wiring diagram
inside the machinery compartment.
NOTE
Wiring Diagrams are contained in Section 6 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
2
SECTION 2 – INSTALLATION
WARNING – After any conversions, readjustments, or service work on the oven:
• Check that the ventilation system is in operation.
WARNING - Keep the appliance area free and clear of combustibles.
WARNING – The oven must be installed on an even (level) non-flammable flooring and any adjacent walls
must be non-flammable. Recommended minimum clearances are specified in the Description section of
this manual.
WARNING – Do not obstruct the flow of combustion and ventilation air to and from your oven. There must
be no obstructions around or underneath the oven. Constructional changes to the area where the oven
is installed shall not affect the air supply to the oven.
CAUTION: To reduce the risk of fire, the appliance is to be mounted on floors of noncombustible construction with
noncombustible flooring and surface finish and with no combustible material against the underside thereof, or on
noncombustible slabs or arches having no combustible material against the underside thereof, such construction
shall in all cases extend not less than 12 inches (304mm) beyond the equipment on all sides.
CAUTION: For additional installation information, contact your local Authorized Service Agent.
NOTE – There must be adequate clearance between the oven and combustible construction. Clearance must also
be provided for servicing and for proper operation.
NOTE – An electrical wiring diagram for the oven is located inside the machinery compartment.
NOTE: All aspects of the oven installation, including placement, utility connections, and ventilation requirements,
must conform with any applicable local, national, or international codes. These codes supersede the requirements
and guidelines provided in this manual.
NOTE: In the USA, the oven installation must conform to local codes. Electric ovens, when installed, must be
electrically grounded in accordance with local codes, or in the absence of local codes, with the National Electrical
Code (NEC), or ANSI/NFPA70.
NOTE: In Canada, the oven installation must conform with local codes. Electric ovens, when installed, must be
electrically grounded in accordance with local codes, or in the absence of local codes, with the Canadian Electrical
Code CSA C22.2.
3
PS640 OVEN INSTALLATION
REQUIRED KITS AND EQUIPMENT
PS640
Electric Oven
Installation
Kit
TYPE OF INSTALLATION
P/N47810-0008
PS640
Single Oven
Option Base w/
15″ Legs,
Casters & Top
Kit
P/N59720
1
1
PS640 Single Electric Oven
PS640 Double Electric Oven
2
PS640 Triple Electric Oven
3
PS640
DoubleOven
OptionBase w/
6″ Legs,
Casters & Top
Kit
P/N59725
PS640
TripleOven
OptionBase w/
Casters& Top
Kit
P/N59726
1
1
PARTS LIST FOR SERIES PS640 ELECTRIC OVEN
INSTALLATION KIT
P/N 47810-0008
(Two required for double oven)
(Three required for triple oven)
ITEM
NO.
QTY
PART NO.
1
1
55028
DESCRIPTION
CONVEYOR END STOP
2
1
55027
CONVEYOR LEFT REAR STOP
3
1
42612
SERVICE AGENCY DIRECTORY
4
1
22500-0080
5
1
51054
LABEL, MM
ASSY, HANDLE & DOOR
Figure 2-1. PS640-Series Electric Oven Installation Parts
1
2
5
4
3
4
Figure 2-2. Model PS640 Single Oven
Option Base with Legs and Top
1
8
HARDWARE BAG
5, 6, 7, 10 & 11
3
4
2
9
PARTS LIST FOR PS640 SERIES SINGLE OVEN OPTION - BASE w/15″″ LEGS & TOP
P/N 59720
ITEM NO.
QTY
PART NO.
DESCRIPTION
1
1
60287
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 CASTER FLAT PLATE
5
32
220373
3/8″-16 × 1″ HEX SCREW, SST
6
32
21416-0001
3/8″ FLAT WASHER, SS
7
32
21422-0001
3/8″ SPLIT LOCK WASHER, ZP
8
1
22450-0228
RESTRAINT CABLE ASSEMBLY
9
1
59560
TOP COVER
10
2
59677
SCR, MS SL TR HD 10-32 × 2-1/2″
11
2
7A2S15
SCR, MS STR TRSHD 10-32 × 3/4″
5
Figure 2-3. Model PS640 Double Oven
Option Base with Legs and Top
1
8
HARDWARE BAG
5, 6, 7, 10 & 11
3
4
2
9
PARTS LIST FOR PS640 SERIES DOUBLE OVEN OPTION - BASE w/6″″ LEGS & TOP
P/N 59725
ITEM NO.
QTY
PART NO.
1
1
60287
DESCRIPTION
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
SWIVEL CASTER FLAT PLATE
5
32
220373
3/8″-16 × 13 HEX SCREW, SST
6
32
21416-0001
3/8″ FLAT WASHER, SS
7
32
21422-0001
3/8″ SPLIT LOCK WASHER, ZP
8
1
22450-0228
RESTRAINT CABLE ASSEMBLY
9
1
59560
TOP COVER
10
2
59677
SCR, MS SL TR HD 10-32 × 2-1/2″
11
2
7A2S15
SCR, MS STR TRSHD 10-32 × 3/4″
6
Figure 2-4. Model PS640 Triple Oven
Option Base with Outriggers and Top
1
15
HARDWARE BAG
7, 8, 9, 10, 11, 12,
13, 14, & 17
3
5
4
6
2
16
PARTS LIST FOR PS640 SERIES TRIPLE OVEN OPTION - BASE w/CASTERS & TOP
P/N 59726
ITEM NO.
1
QTY
1
PART NO.
60287
DESCRIPTION
COMPLETE BASE WELDMENT
2
4
45209
3
2
22290-0009
SWIVEL CASTER, W/BRAKE FLAT PLATE
4
2
22290-0010
SWIVEL CASTER, FLAT PLATE
5
4
45206
INSERT,QUAD ADJUSTMENT FOOT
6
4
45205
SPACER,QUAD CASTER
7
32
A27727
3/83 -16x1-1/4 HEX BOLT
8
32
A21924
3/83 FLAT WASHER, SS
9
32
21422-0001
3/83 SPLIT LOCK WASHER, ZP
10
16
21172-0004
3/83 -16 NYLON INSULATED LOCKNUT, ZC
11
8
2001048
1/23 -13 x 1-3/8 18-8 HEX CAPSCREW
12
8
A27750
1/23 18-8 FLAT WASHER
13
8
21422-0016
1/23 18-8 LOCK WASHER
QUAD OUTRIGGER WELDMENT
14
2
59677
SCR, MS SL TR HD 10-32X2-1/2
15
1
22450-0228
RESTRAINT CABLE ASSEMBLY
16
1
59560
17
2
7A2S15
TOP COVER
SCR, MS STR TRSHD 10-32X3/4″
7
B. Recommendations
III. VENTILATION SYSTEM
NOTE THAT THE HOOD DIMENSIONS SHOWN IN
FIGURE 2-5 ARE RECOMMENDATIONS ONLY.
LOCAL, NATIONAL AND INTERNATIONAL CODES
MUST BE FOLLOWED WHEN INSTALLING THE
VENTILATION SYSTEM. ANY APPLICABLE CODES
SUPERSEDE THE RECOMMENDATIONS SHOWN IN
THIS MANUAL.
IMPORTANT
Where national or local codes require the installation of fire suppression equipment or other
supplementary equipment, DO NOT
mount the
equipment directly to the oven.
MOUNTING SUCH EQUIPMENT ON
THE OVEN MAY:
• VOID AGENCY CERTIFICATIONS
• RESTRICT SERVICE ACCESS
• LEAD TO INCREASED SERVICE
EXPENSES FOR THE OWNER
The rate of air flow exhausted through the ventilation system
may vary depending on the oven configuration and hood
design. Consult the hood manufacturer or ventilation engineer
for these specifications.
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 heatrelated problems to the oven components as if there were no
ventilation at all. The best method of supplying return air is
through the heating, ventilation and air conditioning (HVAC)
system. Through the HVAC system, the air can be temperature-controlled for summer and winter. Return air can also be
brought in directly from outside the building, but detrimental
effects can result from extreme seasonal hot and cold temperatures from the outdoors.
A. Requirements
NOTE: Return air from the mechanically driven system must
not blow at the opening of the baking chamber. Poor
oven baking performance will result.
A mechanically driven ventilation system is STRONGLY
RECOMMENDED for electric oven installations.
PROPER VENTILATION OF THE OVEN IS THE RESPONSIBILITY OF THE OWNER.
C. Other ventilation concerns
•
Special locations, conditions, or problems may require
the services of a ventilation engineer or specialist.
•
Inadequate ventilation can inhibit oven performance.
•
It is recommended that the ventilation system and duct
work be checked at prevailing intervals as specified by the
hood manufacturer and/or HVAC engineer or specialist.
Figure 2-5. Ventilation System
18″ (458mm)
minimum
(Typical - both
ends of oven)
2″ (51mm)
minimum
8
8″ (203mm)
minimum
3″ (76mm)
minimum
Figure 2-6. Leg extension and casters installation
IV. ASSEMBLY
A. Top Panel and Base Pad Assembly
1.
Install the four leg extensions onto the base pad using
the 3/8″-16 × 1″ screws, 3/8″ flat washers, and
3/8″ lockwashers supplied in the Base Pad Kit. See
Figure 2-6. Check that the finished sides of each leg
extension face OUTWARDS. One rear leg should be
attached using three 3/8″-16 × 1″ screws and the 3/4″
eyebolt, as shown in Figure 2-6. This eyebolt acts as the
anchor point for the restraint cable assembly (see Part C,
Restraint Cable Installation).
2.
If your oven is equipped with the lower shelf, position it in
place as shown in Figure 2-6. Check that the lip on the
shelf faces DOWN. Seal joint between leg and shelf with
NSF listed silicone.
3.
Install one caster onto each leg extension, as shown in
Figure 2-7. Use the 3/8″-16 × 1″ screws, 3/8″ flat washers, and 3/8″ lockwashers supplied in the Installation Kit.
The locking casters should be installed at the FRONT of
the oven. The non-locking casters should be installed at
the REAR of the oven.
4.
5.
Finished sides of
leg extension face
corner of base
pad
Lower
shelf
Domestic and
standard export
ovens:
Locking casters FRONT of oven
Non-locking casters REAR of oven
Install the lower oven cavity onto the base pad.
See Fig 2-7.
For single ovens ONLY:
3/8″ flat
washer
Install the top panel using the screws included in the base
pad kit, as shown in Figure 2-8. Then, skip ahead to Part
C, Restraint Cable Installation.
3/8″ lock
washer
For double or triple ovens:
3/8″-16 × 1″
hex screw
Continue on to Part B, Stacking. Note that the top panel
should NOT be installed for double and triple ovens until
after stacking the oven cavities.
Figure 2-7. Base pad Installation
Figure 2-8. Top panel installation
Bottom oven•
cavity
#10-32 × 2-1/2″
screw length
#10-32 × 3/4″
screw length
Assembled•
base pad
9
Top
panel
C. Restraint Cable Installation
NOTE: DO NOT install top panel onto double or triple
ovens until AFTER stacking the oven cavities. See
Part B, Stacking.
For single ovens, skip ahead to Part C, Restraint Cable
Installation.
Because the oven is equipped with casters, a restraint cable
assembly must be installed to limit the movement of the appliance without depending on the connector and the quick disconnect device or its associated piping. One end of the cable is
anchored to the eyebolt on the rear surface of the oven’s base
pad, while the other is anchored to the wall. See Figure 2-11.
IMPORTANT
Middleby Marshall STRONGLY RECOMMENDS that PS640
Gas oven cavities be stacked BY AUTHORIZED PERSONEL.
After connecting the restraint cable, move the oven to its final
location. Adjust the bottom (hex) sections of the feet so that
the casters are off the floor. For quad ovens, lock the two
front casters.
Contact your Middleby Marshall Authorized Service Agent for
complete stacking instructions.
Figure 2-10. Top panel installation
B. Stacking
1.
Stack an oven cavity on top of the lower oven. Check
the following:
#10-32 × 2-1/2″
screw length
• All four sides of the lower lip (on the bottom edge
of the oven cavity) overlap the top of the lower oven
Top
panel
#10-32 × 3/4″
screw length
• The oven is level
• The oven is firmly seated
See Figure 2-9.
2.
For triple ovens, repeat Step 1 to install the top
oven cavity.
3.
Install the top panel using the screws included in the base
pad kit, as shown in Figure 2-10.
Figure 2-9. Stacking
Figure 2-11. Installing the Restraint Cable
Restraint cable assembly
3/8″-18 × 1″
eyebolt on
rear leg
extension
3/4″ (19mm)
eyebolt
Wall of structure
10
D. Conveyor Installation
1.
2.
Figure 2-13. Conveyor placement
Unfold the conveyor as shown in Figure 2-12. Then, begin
to slide the conveyor into the end of the oven. The
conveyor can only be installed from the end of the oven
with the drive motor.
Crumb tray
support
bracket
Continue moving the conveyor into the oven until the
frame protrudes equally from each end of the oven.
Check that the crumb tray supports located on the underside of the conveyor frame rest firmly against the lower
end plugs, as shown in Figure 2-13.
3.
When the conveyor is positioned properly, check for
freedom of movement of the conveyor belt by pulling it for
about 2-3 feet (0.6-1.0m) with your fingers. The drive and
idler shafts must rotate smoothly, and the belt must move
freely without rubbing on the inside of the oven.
4.
Check the tension of the conveyor belt as shown in
Figure 2-14. The belt should lift about 1″ (25mm).
DO NOT OVERTIGHTEN THE CONVEYOR BELT.
End plug
Conveyor
placed in
oven
NOTE: If necessary, the belt tension can be adjusted by
turning the conveyor adjustment screws, located at
the idler (non-control) end of the conveyor. See
Figure 2-14.
Figure 2-12. Conveyor installation
Folded
frame
Figure 2-14. Conveyor Belt tension
Idler end (with belt tension
adjustment screws)
1″ (25mm)
vertical
deflection
Adjustment
screws (2) on
idler end of
conveyor
Drive end (with
drive sprocket)
11
5.
If it is necessary to add or remove conveyor links to
achieve the correct tension, OR if it is necessary to
reverse the conveyor belt for correct orientation, the belt
will need to be removed from the conveyor frame. If this
is necessary, perform the following procedure:
CONVEYOR BELT REVERSAL
Conveyor belt reversal consists of three steps:
• Remove the conveyor assembly from the oven and
place it flat on the floor.
1.
Physically reversing the conveyor belt.
2.
Resetting direction jumper on the conveyor control board.
3.
Switching the photo detector.
REVERSING THE CONVEYOR BELT
• Remove the master links using long-nose pliers. Then,
roll up the belt along the length of the conveyor frame.
Remove the conveyor from the oven and find the master link
location. Remove master links and remove the belt from the
conveyor frame. Reassemble the belt back onto the frame (in
the reverse direction) and reinstall the master links. Replace the
conveyor assembly in the oven.
• Add or remove belt links as necessary to achieve the
correct belt tension.
• Replace the belt on the conveyor frame. Check that the
conveyor belt links are oriented as shown in Figure 2-15,
and that the smooth side of the conveyor belt faces UP.
RESETTING DIRECTION JUMPER
• Connect the inside master links. Check that the links are
oriented as shown in Figure 2-15.
Locate Jumper P1 on the conveyor control board. Move jumper
from terminals 1 and 2, and replace onto terminals 2 and 3.
• Connect the outside master links. Note that the outside
master links each have an open hook on one side. This
hook aligns with the hooks along the sides of the other
conveyor links. See Figure 2-15.
CAUTION:
Shock hazard in compartments electrical filters
are electrically alive.
• Replace the conveyor into the oven.
SWITCHING PHOTO DETECTOR
Figure 2-15. Conveyor and Master Link orientation
CAUTION:
Direction
of travel
CORRECT
master link
position
Remove the three screws securing the access door to the unit.
Open the access door and disconnect the connector fitting to
the photo eye assembly. Remove the two screws securing the
photo eye assembly to the control box. Remove the four nuts
securing the photo eye to the housing. Rotate the photo eye 180
degrees and resecure the photo eye with the four nuts.
Incorrect
master link
position
E.
Final Assembly
1.
Install the crumb trays underneath the conveyor as shown
in Figure 2-16.
Disconnect Power Before Switching Photo eye.
On the opposite control box, remove the two screws holding the
cover where the photo eye assembly will be positioned. Secure
the photo eye assembly in position with the two screws. Place
the photo eye cover on the opposite control box, where the
photo eye assembly was removed, and secure the two screws.
Secure the access door with the three screws.
Remove the three screws securing the access door on the
opposite side. Open the access door, where the photo eye is
now positioned, and connect the photo eye connector fitting.
Secure the access door with the three screws.
Figure 2-16. Crumb Trays
Apply power to the unit. Adjust the photo eye height by loosening the two screws securing the photo eye assembly and sliding
the photo eye assembly either up or down, such that the beam
is approximately 1/4 inch above the belt.
Note:
This is MUCH easier in reduced light.
Replace all covers.
Crumb tray
insertion
12
III. ELECTRICAL CONNECTION INFORMATION
FOR PS640E-SERIES OVENS.
IV. ELECTRIC SUPPLY FOR ELECTRICALLY
HEATED OVENS
Power requirements for electrically heated ovens are usually
208 - 240VAC, 3-phase, 4-wire (3 ‘hot’, 1 ground), although
ovens built for export can have power requirements of 380VAC
and 480VAC. (These ovens have a 5-wire system.) A 2″
(51mm) diameter cutout/hole in the back of the machinery
compartment provides access for the electrical supply connections. Using flexible cable(s) for the electrical power supply
conductors requires a 2″ (51mm) strain-relief fitting (not furnished) to enable safe access to the terminal block from which
oven power is distributed.
WARNING
Authorized supplier personnel normally accomplish the connections for the ventilation system,
electric supply, as arranged by the customer.
Following these connections, the factory-authorized installer can perform the initial startup of
the oven.
The supply conductors must be of the size and material
(copper) recommended to provide the current required; (refer to
the data plate for the ampere specifications). The electric
current rating for each conductor supplying a PS640E-Series
Oven must comply to local and national codes.
Check the oven data plate (Figure 2-17) before making any
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.
Typical specifications for each PS640E-Series Oven are
208V or 240V, 3-phase, 4-wire, 60-ampere, 34.4kW. A PS640ESeries Double Oven (Figure 1-2) installation would require two
60-ampere service connections, one for each oven; the 34.4kW
power consumption also doubles for such an installation to
68.8kW.
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/ circuit breaker have
lockout/tagout capability. The electric supply connection must
meet all national and local electrical code requirements. Copper is the recommended material for the electrical supply
conductors.
The 208V or 240VAC electrically heated oven uses two legs of
the supplied power to provide 208V or 240VAC power for the
oven control circuitry.
Electrical Junction Box
(One per oven cavity)
Figure 2-18. Utility Connection Locations for
Electric Ovens
Figure 2-17. Typical Electric Oven Data Plate
13
UTILITY ROUGH-IN DIMENSIONS AND POSITIONING
FOR PS640-SERIES OVENS
WARNING
DO NOT USE CONDUIT FOR GROUND
CONNECTION.
To Oven
CAUTION
IT IS RECOMMENDED THAT THE OVEN
BE PLACED UNDER A VENTILATION
HOOD FOR ADEQUATE AIR SUPPLY
AND VENTILATION.
To Oven
ELECTRIC SUPPLY TO BE
PROVIDED BY CUSTOMER
Suggested dimensions are shown; utility code
requirements supersede any factors shown.
CIRCUIT BREAKER
Figure 2-19. Typical PS640-Series Oven(s)
Installation
Separate circuit breaker with lockout/tagout electrical shutoff
for each oven. Wire each oven separately.
100 Amp circuit breaker for 208-240V, or 50 Amp circuit
breaker for 380-480V.
ELECTRICAL RATING
34.4 kW/hr.
ELECTRICAL SPECIFICATIONS
SUPPLY WIRE
DOMESTIC: 208V main blower motors and elements,
3 Ph, 75 Amp draw, 50/60 Hz, 208-240V control circuit,
3 pole, 4 wire system per oven (3 hot, 1 grd).
Supply wire size must be in accordance with the National
Electrical Code (current edition) and must be in compliance with
local codes.
Do NOT use conduit for ground.
NOTE: The electrical terminal connection marked “MP” located
inside the control compartment is desiganated for the blue
(neutral) wire to the oven. See the electrical wiring/schematics
in Section 6 of this manual.
or
DOMESTIC: 240V main blower motors and elements,
3 Ph, 65 Amp draw, 50/60 Hz, 208-240V control circuit,
3 pole, 4 wire system per oven (3 hot, 1 grd).
SUGGESTED
Do NOT use conduit for ground.
If space permits, service should be located near the control
console end of the oven(s) to allow convenient access to safety
switches.
or
EXPORT: 380V elements, 3 Ph, 40 Amp draw, 50/60 Hz,
208-240V control circuit and main blower motor, 4 pole,
5 wire system per oven (3 hot, 1 neutral, 1 grd).
Do NOT use conduit for ground.
or
DOMESTIC: 480V elements, 3 Ph, 32.5 Amp draw,
50/60 Hz, 208-240V control circuit and main blower motor,
4 pole, 5 wire system per oven (3 hot, 1 neutral, 1 grd).
Do NOT use conduit for ground.
14
SECTION 3 - OPERATION
C. Temperature Control Display
E. Message Bar
Increase
Decrease
A. Main On/Off Button
B. Conveyor Time Setting
D. TEMP Set
Right
Left
LOCATION AND DESCRIPTION OF CONTROLS
A. Main On/Off Button
C. Temperature Control/Display
Turns all oven functions on or off. If the oven is below the set
point, it will rise to the set point and turn the conveyor on. If it is
turned off and the oven is above 200° F, the blowers will remain
on until the oven drops below 200° F.
Displays the set point of the oven.
D. TEMP Set
Pressing on the “TEMP” button shows individual displays and
combined adjustments.
B. Conveyor Time Setting
E.
Adjusts and displays the conveyor bake time. Dual belt ovens
have two displays, single units have one.
Message Bar
Indicates various messages pertaining to current oven
conditions.
15
NORMAL OPERATION - STEP-BY-STEP
2.
A. Main Screen
1.
When the unit has been “OFF” for more than 1 minute
the controller will display the screen saver, as shown in
Figure 3-1. To start operation, push the “Enter/Reset”
button. The controller will display the “OFF” screen, as
shown in Figure 3-2.
Push the “ON/OFF” button to start the oven. The controller will display the screen, as shown in Figure 3-3.
Figure 3-3 Main Screen ON
Figure 3-1 Screen Saver
FRONT BELT JAMMED
450 F
BELT 01 SPEED
4m
ON
The Middleby Corporation
1400 Toastmaster Drive
Elgin, IL 60120
Phone: 847-741-3300
Fax:
847-741-0015
.
.
30s
©2005 Middleby Corporation,All rights reserved
ON/OFF button
3.
Figure 3-2 Main Screen OFF
The Middleby Corporation
To change the temperature, push the “TEMP” button. The
controller will display the screen, shown in
←”
Figure 3-4. To change the temperature, push the “←
arrow button. Then push either the “↑” arrow or “↓” arrow
buttons to increase or decrease temperatures respectively. When the proper temperature is entered, push the
“Enter/Reset” button. The controller will now show the
display shown in Figure 3-3.
450 F
BELT 01 SPEED
OFF
4m
.
.
30s
Figure 3-4 Temperature Screen
TEMPERATURE SET UP
ACTUAL TEMP
ON
133.8 F
450.0 F
TEMP Set button
16
4.
To change the conveyor belt speed, push the “TIME”
button. The controller will display the screen, shown in
←”
Figure 3-5. To change the minute setting, push the “←
arrow button. Then push either the “↑” arrow or “↓” arrow
buttons to increase or decrease the time accordingly. To
change the second setting, push the “→” arrow button.
Then push either the “↑” arrow or “↓” arrow buttons to
increase or decrease the time accordingly. When the
proper times are entered, push the “ENTER/RESET” button. The controller will now show the display shown in
Figure 3-3.
C. Daily Shutdown Procedure
1.
Make certain there are no products left on the conveyor in
the oven.
2.
Press the “ON/OFF” button to turn the oven off.
3.
Open the window to allow the oven to cool faster.
4.
After the oven has cooled and the blowers have turned off, the
circuit breaker/fused disconnect may be turned off.
Quick Reference – Touch Screen Controller
A. Main Screen
Figure 3-5 Belt Speed Screen
Message Bar
BELT 01 SPEED
LEFT FOR MINUTES - RIGHT FOR SECONDS
1.
ON/OFF button - Used to turn oven On and Off.
2.
TIME - See Separate Instructions.
3.
TEMP - See Separate Instructions.
4.
Energy level indicators - Indicators to either side of the
screen indicate the energy input to that side of the oven.
5.
Message bar - Indicates various messages pertaining to
current oven conditions.
B. Oven Temperature/Set Point/Indicator Screen
4m. 30s.
1.
Actual temperature - Indicates current average temperature of the right side of the oven.
2.
Set point temperature - Pressing on this value allows the
user to adjust the set point of the oven.
3.
Exit - Returns to the main screen.
C. Energy Modes
Energy Mode One - This mode is automatic, and starts (bake
time +1 minute) after the last product has entered
the oven. In this mode, the main oven blowers will lower to 1200
RPM, while the oven maintains temperature and belt speed.
ON/OFF button
TEMP button
TIME button
B. Daily Startup Procedure
1.
Check that the circuit breaker/fused disconnect is in the On
position. Check that the window is closed. The touch panel
display should be lit.
2.
Adjust the conveyor to the desired bake time.
3.
Press the temperature button to display the oven setting.
Set temperature as desired.
4.
Press the “ON” button to activate the oven. The conveyor
will not run, until the oven temperature has reached the
set points.
17
III. QUICK REFERENCE: TROUBLESHOOTING
SYMPTOM
PROBLEM
SOLUTION
Oven will not
turn On.
No electrical power
•
Check that the circuit breaker/fused disconnect is on.
Make sure the emergenct stop button is on.
Oven will not
heat.
Faulty contactor
•
Replace contactor.
Faulty heater element
•
Replace element.
Oven is operating, but
little or no air is coming
from the fingers.
Air fingers may be assembled incorrectly after
cleaning.
•
Turn oven off, and allow to cool. Reassemble fingers
correctly.
Conveyor will not move.
Conveyor may be jammed.
•
Turn oven off, and allow to cool. Check conveyor for
blockage.
IV. SCREEN ALERTS
SYMPTOM
PROBLEM
Battery Symbol in the
lower right hand corner
The internal battery needs
to be replaced to retain energy mode timings.
•
A qualified service technician should accomplish this.
Clean rear grills.
•
Failure to do this will eventually shut down the oven due to
excessive temperature.
Control Over Temp
Rear Grills are clogged.
•
Clean grills.
Front belt jammed
Front belt has stopped.
•
•
Remove obstruction, and restart oven.
If no obstruction, call service.
Rear Belt jammed
Rear belt has stopped.
•
•
Remove obstruction, and restart oven.
If no obstruction, call service.
High Temp Error
Thermocouple or
PLC malfunction.
•
Call service.
Belt off-Oven not
in temperature
Normal operation until
Oven reaches operating
temperature.
High Control Compartment
Temperature
Energy Saving Mode 1
SOLUTION
Normal operation.
18
SECTION 4 - MAINTENANCE
WARNING
Before ANY cleaning or servicing of the oven, perform the following procedure:
1. Switch off the oven and allow it to cool. Do NOT service the oven while it is warm.
2. Turn off the electric supply circuit breaker(s) and disconnect the electric supply to the oven.
When all cleaning and servicing is complete:
1. If the oven was moved for servicing, return the oven to its original location.
2. If the restraint cable was disconnected to clean or service the oven, reconnect it at this time.
3. Reconnect the electrical supply.
4. Turn on the electric supply circuit breaker(s).
5.
Perform the normal startup procedure.
WARNING
Possibility of injury from moving parts and electrical shock exists in this oven. Switch off and lockout/tagout
the electric supply BEFORE beginning to disassemble, clean, or service any oven. Never disassemble or clean
an oven with the BLOWER ( ) switch or any other circuit of the oven switched on.
CAUTION
NEVER use a water hose or pressurized steam-cleaning equipment when cleaning this oven. To avoid saturating the oven
insulation, DO NOT use excessive amounts of water. DO NOT use a caustic oven cleaner, which can damage the bake
chamber surfaces.
NOTE
ANY replacement parts that require access to the interior of the oven may ONLY be replaced by a Middleby Marshall
Authorized Service Agent. It is also strongly recommended that the 3-Month Maintenance and 6-Month Maintenance
procedures in this section be performed ONLY by a Middleby Marshall Authorized Service Agent.
I. MAINTENANCE - DAILY
A.
Check that the oven is cool and the power is disconnected, as described in the warning at the beginning of
this Section.
B.
Clean ALL of the cooling fan grills and vent openings
with a stiff nylon brush. Refer to Figure 4-1 for the
locations of the grills and vents.
Figure 4-1. Cooling Vents and Grills
C. Clean the outside of the oven with a soft cloth and mild
detergent.
D. Check that ALL cooling fans are operating properly.
CAUTION:
Vents on
front panel
of oven
If a cooling fan is not operating correctly, it must
be replaced IMMEDIATELY. Operating the oven
without adequate cooling can seriously damage
the oven's internal components.
E.
Clean the conveyor belts with a stiff nylon brush. This
is more easily accomplished by allowing the conveyor to
run while you stand at the exit end of the conveyor.
Then, brush the crumbs off the conveyor as it moves.
F.
Remove and clean the crumb trays. If necessary, refer
to Figure 2-16 (in Section 2, Installation) when replacing
the crumb trays into the oven.
Fan grills (3) on rear
of oven and control
compartment
G. Clean the window in place.
19
Vents (2) on rear
of machinery
compartment
Figure 4-2. Removing Air Fingers and Plates
II. MAINTENANCE – MONTHLY
NOTE: When removing the conveyor, refer to Figure 2-12 (in
Section 2, Installation).
A.
Check that the oven is cool and the power is disconnected,
as described in the warning at the beginning of this Section.
B.
Remove the crumb trays from the oven.
C. Lift the drive end of the conveyor slightly, and push it
forward into the oven. This removes the tension from the
drive chain. Then, remove the drive chain from the conveyor sprocket.
D. Slide the conveyor out of the oven, folding it as it is removed.
NOTE: Split belt conveyors can only be removed from the end
of the oven with the drive motor.
Single-belt conveyor assemblies may be removed
from either end of the oven. If it is to be removed from
the end of the oven without drive motor, remove the
drive motor sprocket as described in the Conveyor
Installation instructions (in Section 2, Installation).
E.
Remove the end plugs from the oven. The end plugs are
shown in Figure 1-1 (in Section 1, Description).
F.
Slide the air fingers and blank plates out of the oven, as
shown in Figure 4-2. AS EACH FINGER OR PLATE IS
REMOVED, WRITE A “LOCATION CODE” ON IT WITH A
MARKER to make sure that it can be reinstalled correctly.
Figure 4-3. Disassembling the Air Fingers
Example of markings:
(Top Row)
(Bottom Row)
T1
B1
T2
B2
T3
B3
T4
B4
T5
B5
T6
B6
G. Disassemble the air fingers as shown in Figure 4-3. AS EACH
FINGER IS DISASSEMBLED, WRITE THE “LOCATION CODE”
FOR THE FINGER ON ALL THREE OF ITS PIECES. This will
help you in correctly reassembling the air fingers.
CAUTION:
Incorrect reassembly of the air fingers will change
the baking properties of the oven.
H. Clean the air finger components and the interior of the
baking chamber using a vacuum cleaner and a damp
cloth. Refer to the boxed warnings at the beginning of this
Section for cleaning precautions.
I.
Reassemble the air fingers. Then, replace them in the
oven, using the “location guide” as a guide.
J.
Replace the end plugs on the oven.
K.
Reassemble the conveyor into the oven. If the drive
sprocket was removed when installing the conveyor,
replace it at this time.
L.
Reattach the drive chain.
M. Check the tension of the conveyor belt as shown in Figure
2-14 (in Section 2, Installation). The belt should lift
between 3 - 4″ (75-100mm). DO NOT OVERTIGHTEN
THE CONVEYOR BELT. If necessary, the belt tension
can be adjusted by turning the conveyor adjustment
screws, located at the idler (right) end of the conveyor.
N. Replace the crumb trays.
20
III. MAINTENANCE – EVERY 3 MONTHS
A. Check that the oven is cool and the power is disconnected, as described in the warning at the beginning of
this Section.
B. Vacuum both of the blower mounts, and their surrounding
compartments, using a shop vacuum.
8.
Reassemble the idler shaft into the conveyor. Make
sure that the bronze washer is in place between the
two sections of the shaft. See Figure 4-4.
9.
Replace the conveyor adjustment screws as shown in
Figure 4-4. To allow the conveyor belt to be reinstalled
later, do not tighten the screws at this time.
C. Tighten all electrical terminal screws.
10. Loosen the set screw on both of the conveyor drive
sprockets. Then, remove the sprockets from the shaft.
D. Split Belt Disassembly and Cleaning
11. Check the conveyor configuration as follows:
1.
Refer to Part D, Conveyor Installation, in the Installation section of this Manual. Then, remove the following
components from the oven:
High-speed conveyors are equipped with large flange
bearings at both ends of the shaft, as shown in
Figure 4-5. For these conveyors, remove the two
screws that hold each bearing to the conveyor frame.
With the screws removed, lift the end of the shaft at the
front of the oven, and pull the entire assembly free of
the conveyor frame.
• Conveyor end stop
• Crumb trays
• Chain cover
Standard conveyors are equipped with bronze bushings mounted on spacers at both ends of the shaft, as
shown in Figure 4-5. For these convey-ors, remove
the two screws that hold the bracket to the conveyor
frame. With the screws removed, lift the end of the
shaft at the front of the oven, and pull the entire
assembly free of the conveyor frame. The brackets
will be removed along with the drive shaft assembly.
• Drive chains
• End plugs
• Conveyor assembly
2.
Remove the master links from each conveyor belt.
Then, roll the belts up along the length of the conveyor
to remove them from the frame.
3.
Remove the two conveyor adjustment screws from
the idler end of the conveyor frame, as shown in
Figure 4-4.
4.
Remove the idler shaft assembly from the conveyor.
5.
Pull apart the two sections of the idler shaft.
6.
Clean the shafts thoroughly using a rag. Then, lubri-cate
both the extended shaft and the interior of the hollow
shaft using a light food-grade lubricant. DO NOT
lubricate the shafts using WD40 or a similar product.
This can cause the shafts to wear rapidly.
7.
12. Disassemble and lubricate the two sections of the
drive shaft as described for the idler shaft, above.
13. Before reassembling the shafts into the conveyor
frame, check that they are oriented properly.
14. Reassemble the drive shaft into the conveyor. Make
sure that the bronze washer is in place between the
two sections of the shaft. See Figure 4-4.
15. Replace the drive sprockets. Reassemble the belts
and master links onto the conveyor.
16. Reinstall the end plugs and conveyor onto the oven.
Before reassembling the shafts into the conveyor
frame, check that they are oriented properly.
17. Reattach the drive chains. Replace the chain cover.
18. Check the tension of the conveyor belt as shown in
Figure 2-14 (in Section 2, Installation). The belt should
lift about 1″ (25mm). If necessary, adjust the belt
tension by turning the conveyor adjustment screws.
Figure 4-4. Disassembling the idler shaft
19. Replace all components onto the oven.
Figure 4-5. Drive shaft configurations
21
Figure 4-7. Rear panel access
Figure 4-6. Disassembling the drive shaft
Remove eight (8)
screws to remove
rear panel
Bearings
(2 total)
Blower belt
Blower motor
Loosen four (4) screws to adjust
motor position and belt tension
IV. MAINTENANCE - EVERY 6 MONTHS
E. Blower Belt
1.
Remove the eight screws shown in Figure 4-7. Then,
remove the rear panel from the oven.
2.
Check the blower belt for the proper 1/4″ (6mm) deflection at the center, and for cracking or excessive wear.
See Figure 4-7. Overtightening the belt will cause premature
bearing failure and possible vibrations. A loose belt may also
cause vibrations.
3.
If necessary, adjust the tension of the belt by loosening
the four motor mounting bolts. Reposition the motor as
neccessary until the correct 1/4″ (6mm) deflection is
reached, then tighten the bolts.
A.
Check that the oven is cool and the power is disconnected, as described in the warning at the beginning of
this Section.
B.
Check for excessive wear on the conveyor drive motor
brushes. The brushes should be replaced if they have
worn to less than 1/4″ (6mm) in length. Be sure to replace
the brushes in exactly the same position.
C. For gas ovens, inspect and clean the burner nozzle and
the spark electrode assembly.
D. Check the conveyor drive shaft bushings and spacers.
Replace the components if they are worn.
22
V. KEY SPARE PARTS – Available separately. See Figure 4-8.
1
2
3
4
5
8
11, 12
6
9
7
10
18
17
13, 14, 15, 16
23
22
Figure 4-8. Key Spare Parts
ITEM QTY.
P/N
DESCRIPTION
1
1
60191
DIGITAL DISPLAY, PROGRAMMED
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
2
58920
58679
60196
59668
57288
33983
51399
97525
50610
44914
44568
59942
60197
60198
50589
60091
60638
60683
58668
58669
59132
CONVEYOR DRIVE MOTOR W/PICKUP ASSY.
CONVEYOR SPEED CONTROLER
KIT, THERMOCOUPLE 6″
BELT, BLOWER
MOTOR, BLOWER, 2HP
HIGH LIMIT CONTROL MODULE, 240V
COOLING FAN (BACKWALL)
COOLING FAN (CONTROL COMPARTMENT)
AIR SWITCH
CONTROLLER, POWER 208V/240V
CONTROLLER, POWER 380V/480V
HEATER 208V 34.4kW
HEATER 240V 34.4kW
HEATER 380V 34.4kW
HEATER 480V 34.4kW
PHOTOCELL
INVERTER, PROGRAMMED
PLC
THERMOCOUPLE MODULE
CURRENT MODULE
RELAY, DPDT 24V COIL
23
1
M9608
POWER SUPPLY
23
19, 20, 21
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.
Start the oven again. If the oven still does not
heat, call your Middleby Marshall Service Agency.
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.
24
Middleby-Marshall Model Number E208-240 Volt 50/60 Hz, 3 Phase
25
60227 Rev. A4
SECTION 6 - WIRING DIAGRAM
26
Middleby-Marshall Model Number E380-480 Volt 50/60 Hz, 3 Phase
60231 Rev. A4
NOTES
27
WARNING
Improper installation, adjustment, alteration, service or maintenance
can cause property damage, injury or death. Read the installation,
operating and maintenance instructions thoroughly before
installing or servicing this equipment.
NOTICE
During the warranty period, ALL parts replacement and servicing should be performed
by your Middleby Marshall Authorized Service Agent. Service that is performed by
parties other than your Middleby Marshall Authorized Service Agent may void your
warranty.
NOTICE
Using any parts other than genuine Middleby Marshall factory manufactured parts
relieves the manufacturer of all warranty and liability.
NOTICE
Middleby Marshall reserves the right to change specifications at any time.
Middleby is proud to support the Commercial Food Equipment
Service Association (CFESA). We recognize and applaud
CFESA's ongoing efforts to improve the quality of technical
service in the industry.
Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • USA • (847)741-3300 • FAX (847)741-4406
www.middleby.com