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