Page
PS200/220/224 Series PS310/360 Series PS555/570 Series
2002 Middleby Marshall, Inc
technical service manual
This Technical Service Manual includes information
TABLE OF CONTENTS
DISCONNECT THE OVEN FROM ITS ELECTRICAL POWER SUPPLY BEFORE SERVICING
TABLE OF CONTENTS continued
Instructions for Service Kit
Instructions for Service Kits 33984 and
Blower Motor Centrifugal Safety Switch PS360-series
SECTION SEQUENCE OF OPERATION
I. GAS OVEN SEQUENCE OF OPERATION
NOTE PS200VL-series ovens do not include a cooldown feature
SECTION 1 - SEQUENCE OF OPERATION F. High Limit
NOTE Electric oven models use a separate High Limit Control Module
SECTION AIR FLOW AND HEAT TRANSFER
Blowers, belts and pulleys
I. TYPES OF HEAT TRANSFER
II. BLOWERS AND BLOWER SPEED
Air finger operation
PS300/350 air finger with shutter plate
Current standard air finger all oven models
B. PS360-series ovens
3D air finger label if present
Internal air finger chart
B. Configuration and Alignment
C. Performing a Test Bake
Front-to-back uneven bake
D. PS300/350 Air Finger Shutter Adjustment
PS300/350-style air finger with adjustable shutter plate
Figure 9 - Conveyor Speed Bake Time
Figure 11 - Time of Delivery
Figure 10 - Belt Time
IV. OVEN CAPACITY
SECTION SERVICING COMPONENTS
Original-style speed controller
Current-style speed controller
4 or 8 DIP switches select oven model
PS350-style pickup assembly used on early PS360
Old-style pickup assembly
2. Current-style pickup assembly see Figures
C. Preparing to Service the Speed Controller
Current pickup assembly - side view
Current pickup assembly end view
Field Tester for Conveyor Drive Motor
D. Controller/Motor Failure
1. IF THE GEAR MOTOR RUNS AT FULL SPEED
E. Basic Troubleshooting Flowcharts
2. IF THE GEAR MOTOR WILL NOT RUN AT ALL
SECTION 3 - SERVICING COMPONENTS
Middleby no longer stocks parts for the
with a current model
F. Initial Troubleshooting
120VAC supply. Wire colors vary by oven model
Connections are reversed if conveyor direc- tion is reversed
Connections for pickup test
J. Unshielded Pickup Wires on Early PS360-series ovens
G. Conveyor Control Pickup Test
H. Conveyor Motor Test
Wiring for PS360 Shielded Pickup Cable - early terminal block design
Wiring for PS360 Shielded Pickup Cable - late terminal block design
K. Appendices
Speed Controller Kit with Thumbwheel, P/N 42810-0133, 4/95
SECTION 3 - SERVICING COMPONENTS
Speed Controller Kit with Thumbwheel, P/N 42810-0133, 4/95
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions for Service Kit
Conveyor Speed Controller Kit with Thumbwheel, 4/95
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions for Service Kit
Conveyor Speed Controller Kit with Thumbwheel, 4/95
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions for Service Kit
Conveyor Speed Controller Kit with Thumbwheel, 4/95
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions for Service Kit
Conveyor Speed Controller Kit with Thumbwheel, 4/95
SECTION 3 - SERVICING COMPONENTS
Service Bulletin
Middleby Cooking Systems Group
Conveyor Speed Controller with Digital Display, P/N 37337, 8/00
SUBJECT
Middleby Corporation Service Hotline
Conveyor Speed Controller Kit for PS200R68-series ovens
for PS200R68-series Ovens, 2/02
Instructions for Service Kit
Appendix - Service Bulletin MM-189 - New Conveyor Gear Motors
Brushes, and Pickup Clamps, 8/01
Service Bulletin
Middleby Cooking Systems Group
Appendix - DIP switch settings for Conveyor Speed Controller
with Digital Display P/N 37337, 4/02
II. TEMPERATURE CONTROLLER
Figure 22 - Temperature controllers AB DEFG
A. Part Number Reference - Temperature Controllers
P/N 36056 G - Service Kit P/N
P/N 46837 G - Service Kit P/N
Appendix - Temperature controller terminal cross-reference, 4/02
B. Description
E. Appendices
Digital Temperature Controller
Instructions for Service Kit
Installation, Programming and Troubleshooting Instructions
Middleby Corporation Service Hotline
Controller Types
Installation
Before you Begin
Electrical Connections
Figure 4a
Figure 5a
Figure 5b
Figure 4b
Jumper Setting
Programming
Controller Service Instructions
Temperature
Page 7 of
Diagnostic Error Messages
Page 8 of
Digital Temperature Controller P/N Operating Instructions
Service Key
Display
Unlock Key
Middleby Corporation Service Hotline
Middleby Cooking Systems Group 1400 Toastmaster Drive Elgin, IL
847 741-3300 FAX 847
Appendix - Service Bulletin MM-136 - Electrical Noise
Filter Capacitor Assembly on Temperature Controllers, 9/93
SECTION 3 - SERVICING COMPONENTS
Appendix - Service Bulletin MM-136 - Electrical Noise
Filter Capacitor Assembly on Temperature Controllers, 9/93
SECTION 3 - SERVICING COMPONENTS
Figure 23 - High limit control modules Shown in PS360-series oven
C. Operation and Troubleshooting
III. HIGH LIMIT CONTROL MODULE
A. Part Number Reference - High Limit Control Mod- ules
High Limit Conversion Kit for PS300, 310, 350, & 360 Ovens
High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99
Appendix - Instructions for Service Kit
Instructions for Service Kit
Appendix - Instructions for Service Kit
B. INSTALLATION
High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99
Page 2 of
Appendix - Instructions for Service Kit
High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99
NOT TO SCALE
High limit thermocouple location lower oven
Appendix - Instructions for Service Kit
C. WIRING
Lighted Reset Switch Wiring and Installation
Cooldown circuit wiring
Appendix - Instructions for Service Kit
D. TESTING THE INSTALLATION
High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99
Page 5 of
Appendix - Instructions for Service Kit
ovens with a cooldown feature
replacement
High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99
Appendix - Instructions for Service Kit
ovens without a cooldown feature
replacement
High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99
Appendix - Instructions for Service Kit
Middleby Corporation Service Hotline
High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99
A MIDDLEBY COMPANY
Figure 24 - Thermocouples
Troubleshooting
IV. THERMOCOUPLES
A. Part Number Reference - Thermocouples
Page
Oven Thermocouple Kit
Instructions for Service Kits P/Ns 33984 and
KIT CONTENTS - KIT P/N
KIT CONTENTS - KIT P/N
Appendix - Instructions for Service Kits 33984 and
Oven Thermocouple Kit, 11/01
Analog Temperature Controller
Digital Temperature Controller
Appendix - Instructions for Service Kits 33984 and
Thermocouple Installation - PS360 Series
Thermocouple Wiring - PS360 Series
Oven Thermocouple Kit, 11/01
Appendix - Instructions for Service Kits 33984 and
Analog Temperature Controller
Digital Temperature Controller
Oven Thermocouple Kit, 11/01
Appendix - Instructions for Service Kits 33984 and
Digital Temperature Controller
Oven Thermocouple Kit, 11/01
PS536
Appendix - Instructions for Service Kits 33984 and
Oven Thermocouple Kit, 11/01
NOTE FOR HIGH LIMIT THERMOCOUPLES
3. Disconnect the thermocouple leads. Refer to Figure
Appendix - Instructions for Service Kits 33984 and
Oven Thermocouple Kit, 11/01
PS555 Electric and PS555E
NOTE FOR HIGH LIMIT THERMOCOUPLES
Appendix - Instructions for Service Kits 33984 and
Oven Thermocouple Kit, 11/01
3. Remove the rear shrouds. Open the blower motor com- partment doors
Appendix - Instructions for Service Kits 33984 and
Oven Thermocouple Kit, 11/01
High limit thermocouple
position for ovens with
Appendix - Instructions for Service Kits 33984 and
Oven Thermocouple Kit, 11/01
High limit thermocouple
High limit thermocouple
Appendix - Instructions for Service Kits 33984 and
Oven Thermocouple Kit, 11/01
Left
Right
Appendix - Instructions for Service Kits 33984 and
Thermocouple Wiring - PS555G and PS570G
Middleby Corporation Service Hotline
Oven Thermocouple Kit, 11/01
Early-style PS200 indirect drive assembly
Current PS200 indirect drive assembly
Blower motor fuses
V. BLOWERS A. PS200-series ovens
Bearing lubrication
Blower belt tension
Repositioning the blower motor
Loosen bolts to reposition motor and adjust belt tension
Fan shaft alignment tool
Part Number
Description
Not available
Not available
Figure 33 - Four-point alignment test for correct pulley alignment
Cord tied to shaft
Cord must touch sheaves at four points indicated by arrows
date early-style fan shaft assembly to the current version shown here
Part Number
Description
Part Number
Blower motor fuses - single-phase motors
Blower motor fuses - three-phase motors
B. PS360-series ovens
Figure 39 - Blower wheel placement Shown from rear of oven
Figure 37 - Clockwise blower wheel
Figure 38 - Counterclockwise blower wheel
Inlet ring
Figure 42 - PS570/570S blower configuration
Figure 43 - PS555/570G blower configuration
Figure 44 - Fuse/circuit breaker locations
A. PS555/570-series ovens
Part Number Description
Part Number
Description
Oven
PS500-series blower wheel orientation
Bearing lubrication
Blower belt tension and repositioning the blower motor
Figure 48 - Four-point alignment test for correct pulley alignment
Figure 49 - PS360-series blower motor centrifugal safety switch
VI. BLOWER MOTOR CENTRIFUGAL SAFETY SWITCH PS360-SERIES
A. Part Number Reference - Blower Centrifugal Switch
B. Troubleshooting
Figure 50 - Air pressure safety switch models
Dungs square-case “replacement” air switch with screw adjustment
PS360WB70/EWB with Midco burner
PS360WB70/EWB with Wayne burner
B. Troubleshooting
Connects to negative pressure side of air switch
Appendix - Instructions for Service Kits 35624 and
Air Pressure Switch Replacement Kits, 1/97
SECTION 3 - SERVICING COMPONENTS
C. Appendices
Appendix - Instructions for Service Kits 35624 and
Air Pressure Switch Replacement Kits, 1/97
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions to Replace an “Alternate” Air Switch
P/N 36194 with Service Kit P/N 35624, 3/97
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions to Replace an “Alternate” Air Switch
P/N 36194 with Service Kit P/N 35624, 3/97
SECTION 3 - SERVICING COMPONENTS
PS570/570S flame gate adjustment
Adjustment rod
IX. PS570/570S FLAME GATE
A. Part Number Reference - Flame Gate
PS200-series gas train
PS310, PS314, PS360 or PS360WB gas train
X. GAS TRAIN AND BURNER SYSTEM
A. Part Number Reference
PS360EWB or PS360WB70 gas train with Midco burner
PS360EWB or PS360WB70 gas train with Wayne burner
SWITCH
SWITCH
PS570S gas train
PS570G or PS555 gas train
NOT SHOWN components are installed on back wall of machinery
SWITCH
Figure 60 - Wayne burner - exploded view
B. Part Number Reference - Gas Orifices and Gas Conversion Kits
same as
natural gas
Figure 61 - Midco burner
Figure 62 - Wayne burner
C. Component Identification
1. Burner type
Figure 63 - Pilot/ignitor assembly
End of burner without flame target showing pilot shield
Flame targets
D. Pilot/Ignitor Assembly
Flame structure
Figure 67 - Flame rectification Figure 68 - Pilot and probe
Flame Rectification
Voltage
Air shutter adjustment
Temperature
Pilot Application
Burner Blower Motor
Low Flame Bypass Orifice
G. Burner Transformer
H. Burner Motor Relay
I. High Flame Solenoid Valve if so equipped
Figure 71 - Modulating Gas System
Digital Temperature
K. Modulating Gas Valve if so equipped
L. Amplifier Board ovens with a modulating gas valve only
Figure 72 - Combination Gas Control Valve
Burrs in pilot adjustment portal
M. Combination Gas Control Valve
Pilot pressure
N. Ignition Module
P. Burner and Gas Train Troubleshooting
O. Gas Conversion Kits
1. Burner Blower Motor
3. Relay
Voltage Checks for Ignition Module and Combination Gas Valve
8. System Troubleshooting
5. Burner Operation
6. Check Grounding
9. Component Checks Reset System After Lockout
10. Check Spark Ignition Circuit
11. Check Spark Ignitor
Q. Checking the Gas Pressures
R. Troubleshooting Flowcharts
SECTION 3 - SERVICING COMPONENTS
SECTION 3 - SERVICING COMPONENTS
SECTION 3 - SERVICING COMPONENTS
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions for Service Kit Pilot/Ignitor Kit, 7/91
S. Appendices
Appendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions for Service Kit Combination Gas Valve, 1/92
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions for Service Kit Combination Gas Valve, 1/92
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions for Service Kit Combination Gas Valve, 1/92
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions for Service Kit Combination Gas Valve, 1/92
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions for Service Kit Ignition Module, 11/90
SECTION 3 - SERVICING COMPONENTS
Appendix - Instructions for Service Kit Ignition Module, 11/90
SECTION 3 - SERVICING COMPONENTS
Appendix - Position of Combination Gas Valve Components
during Burner Operation, 4/02
SECTION 3 - SERVICING COMPONENTS
TORY BEFORE INSTALLING THIS KIT
ENGLISH- page ESPAÑOL - página
PS360EWB all PS555 all PS570S units produced 4/00 or later
KIT COMPONENTS
ENGLISH
Appendix - Instructions for All Gas Conversion Kits
for Ovens with Wayne Burner, Natural Gas to Propane, 8/00
Typical PS200-series gas train configuration
I. PREPARATION AND DISASSEMBLY
II. COMBINATION GAS CONTROL VALVE SAFETY REGULATORCONVERSION
ENGLISH
Appendix - Instructions for All Gas Conversion Kits
VI. REASSEMBLY
ENGLISH
Appendix - Instructions for All Gas Conversion Kits
for Ovens with Wayne Burner, Natural Gas to Propane, 8/00
IX. PILOT PRESSURE ADJUSTMENT
STAND WELL CLEAR WHEN SWITCHING ON
Remove the pilot adjustment cap screw from the
4. If no leaks are detected by the test, depress the safety
X. MANIFOLD PRESSURE ADJUSTMENT
Appendix - Instructions for All Gas Conversion Kits
for Ovens with Wayne Burner, Natural Gas to Propane, 8/00
XI. MARKING AND LABELING
ENGLISH- page ESPAÑOL - página
KIT COMPONENTS
for Ovens with Wayne Burner, Propane to Natural Gas, 8/00
Propane to Natural Gas Operation
for Ovens with Wayne Burner, Propane to Natural Gas, 8/00
Typical PS200-series gas train configuration
Typical PS300-series gas train configuration
Typical PS555 or PS570S gas train configuration
I. PREPARATION AND DISASSEMBLY
II. COMBINATION GAS CONTROL VALVE SAFETY REGULATORCONVERSION
ENGLISH
Appendix - Instructions for All Gas Conversion Kits
VI. REASSEMBLY
ENGLISH
Appendix - Instructions for All Gas Conversion Kits
for Ovens with Wayne Burner, Propane to Natural Gas, 8/00
IX. PILOT PRESSURE ADJUSTMENT
ENGLISH
Appendix - Instructions for All Gas Conversion Kits
for Ovens with Wayne Burner, Propane to Natural Gas, 8/00
X. MANIFOLD PRESSURE ADJUSTMENT
Appendix - Instructions for All Gas Conversion Kits
for Ovens with Wayne Burner, Propane to Natural Gas, 8/00
SECTION 3 - SERVICING COMPONENTS
Middleby Marshall
PS360EWB and PS360WB70
Natural Gas to Propane Installation Instructions
2. PILOT ORIFICE REPLACEMENT
3. MAIN ORIFICE REPLACEMENT
4. LOW FLAME ORIFICE REPLACEMENT PS360WB70 only
Pilot orifice assembly
Low flame orifice replacement
7. PILOT PRESSURE ADJUSTMENT
8. MAIN MANIFOLD PRESSURE ADJUSTMENT
Gas pressure measurement/adjustment locations
Burner blower configurations
Red “LPG.” label placement on burner housing
Conversion information label placement PS360EWB placement
PS360WB70 placement
9. CONVERSION LABELING
Propane to Natural Gas Installation Instructions
2. PILOT ORIFICE REPLACEMENT
Orifice, Pilot Assembly - Natural Gas, 0.032” 0.81mm
Middleby Marshall
3. MAIN ORIFICE REPLACEMENT
4. LOW FLAME ORIFICE REPLACEMENT PS360WB70 only
Pilot orifice assembly
Low flame orifice replacement
7. PILOT PRESSURE ADJUSTMENT
8. MAIN MANIFOLD PRESSURE ADJUSTMENT
Gas pressure measurement/adjustment locations
Burner blower configurations
Yellow “NAT.” label placement on burner housing
9. CONVERSION LABELING
NATURAL
14” W.C./34.9mbar
Appendix - Equivalent Orifice Sizes at High Altitudes
Includes 4% reduction for each 1000 ft. above sea level, 4/02
SECTION 3 - SERVICING COMPONENTS
PS200 electric early with mercury contactors and fuses
PS200 electric current with solid state
relays and circuit breaker blocks
XI. ELECTRIC OVEN HEATING SYSTEM A. PS200-series ovens
Removing elements
Individual element electrical data
Electrical leads disconnected
Removing the element bank mounting bolts
B. PS310/360-series ovens
Part No. Description
Element bank removed - spacer bracket visible
Individual element electrical data
107W
Spacer brackets
Refer to Temperature Controller on Page
Heating element assembly
Heating element assembly
Heating element assembly
PS555 electric oven heating element removal
cover
D. Mercury Contactor Replacement
Place a deep well socket over the new Tinnerman clip
SECTION 3 - SERVICING COMPONENTS
SECTION ELECTRICAL WIRING DIAGRAMS
I. COMPONENT WIRING
SECTION 4 - ELECTRICAL WIRING DIAGRAMS B. Ignition Modules
II. PS200-SERIES OVENS
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
PAGE 1 OF
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
PAGE 2 OF
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
PS200-series electric oven USA version, 208/240V main blower motor and heating elements, 120V control circuit
220-240V, 50/60 Hz, 3 Ph, 3 pole, 4 wire supply 3 hot, 1 ground
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
SECTION 4 - ELECTRICAL WIRING
DIAGRAMS
III. PS360-SERIES OVENS
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
SECTION 4 - ELECTRICAL WIRING
DIAGRAMS
III. PS555/570-SERIES OVENS
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
PS555 gas oven early, 208/240V main blower motor and control circuit
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
208/240V, 50/60 Hz, 3 Ph, 3 pole, 4 wire supply 3 hot, 1 ground
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
25-point preventative maintenance checklist
SECTION
REFERENCE
Fractional inches to decimal and millimeter equivalents
Decimal equivalents of drill sizes
SECTION 5 - REFERENCE
General conversion factors
Pressure conversions
MULTIPLY
TO OBTAIN
Pressure conversion chart
Ohm’s Law equation wheel
Common electrical wiring diagram symbols
SECTION 5 - REFERENCE
Common electrical wiring diagram symbols continued
SECTION 5 - REFERENCE
Common electrical wiring diagram symbols continued
SECTION 5 - REFERENCE
Common electrical wiring diagram symbols continued
SECTION 5 - REFERENCE
Commercial Food Equipment Service Association CFESA
2002 Middleby Marshall, Inc
Middleby is proud to support the
