Manuals / Middleby Marshall / Kitchen Appliance / Double Oven

Middleby Marshall PS360, PS570, PS200 English, Appendix - Instructions for All Gas Conversion Kits

Models: PS224 PS310 PS220 PS555 PS200 PS360 PS570

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SECTION 3 - SERVICING 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

Burner blower

Solenoid

valve

Pilot line
Combination gas
control valve
(safety regulator)		Burner
		Burner
	Bypass	Pilot pressure
	Bypass	tap (pilot tee)
	line	tap (pilot tee)
	line
Gas pipe union

Typical PS300-series gas train configuration

Burner blower

	Solenoid valve
	(if so equipped)
Combination gas
control valve
(safety regulator)	Bypass
	line	Burner
		Burner
Gas pipe
union
		Pilot line
Manual
shutoff valve		Pilot pressure tap (pilot tee)

Modulating gas

valve (if so equipped)

Typical PS555 or PS570S gas train configuration

		Modulating gas
	Burner	valve (if so
	Burner	equipped)
Burner	blower	equipped)

Solenoid valve (if so equipped)

Combination gas

control valve

(safety regulator) Bypass line

Pilot line

Manual	Gas pipe	Pilot pressure
Manual	Gas pipe	tap (pilot tee)
shutoff valve	union

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Middleby Marshall PS360, PS570, PS200, PS555, PS220, PS224 PS310 English, Appendix - Instructions for All Gas Conversion Kits

Contents

Page 2002 Middleby Marshall, Inc PS200/220/224 Series PS310/360 Series PS555/570 Seriestechnical service manual This Technical Service Manual includes informationDISCONNECT THE OVEN FROM ITS ELECTRICAL POWER SUPPLY BEFORE SERVICING TABLE OF CONTENTSInstructions for Service Kit TABLE OF CONTENTS continuedInstructions for Service Kits 33984 and Blower Motor Centrifugal Safety Switch PS360-seriesI. GAS OVEN SEQUENCE OF OPERATION SECTION SEQUENCE OF OPERATIONSECTION 1 - SEQUENCE OF OPERATION F. High Limit NOTE PS200VL-series ovens do not include a cooldown featureNOTE Electric oven models use a separate High Limit Control Module Blowers, belts and pulleys SECTION AIR FLOW AND HEAT TRANSFERI. TYPES OF HEAT TRANSFER II. BLOWERS AND BLOWER SPEEDPS300/350 air finger with shutter plate Air finger operationCurrent standard air finger all oven models B. PS360-series ovensInternal air finger chart 3D air finger label if presentB. Configuration and Alignment C. Performing a Test BakeD. PS300/350 Air Finger Shutter Adjustment Front-to-back uneven bakePS300/350-style air finger with adjustable shutter plate Figure 11 - Time of Delivery Figure 9 - Conveyor Speed Bake TimeFigure 10 - Belt Time IV. OVEN CAPACITYOriginal-style speed controller SECTION SERVICING COMPONENTSCurrent-style speed controller 4 or 8 DIP switches select oven modelOld-style pickup assembly PS350-style pickup assembly used on early PS3602. Current-style pickup assembly see Figures C. Preparing to Service the Speed ControllerCurrent pickup assembly end view Current pickup assembly - side viewField Tester for Conveyor Drive Motor D. Controller/Motor FailureE. Basic Troubleshooting Flowcharts 1. IF THE GEAR MOTOR RUNS AT FULL SPEEDSECTION 3 - SERVICING COMPONENTS 2. IF THE GEAR MOTOR WILL NOT RUN AT ALLMiddleby no longer stocks parts for the with a current model120VAC supply. Wire colors vary by oven model F. Initial TroubleshootingConnections are reversed if conveyor direc- tion is reversed J. Unshielded Pickup Wires on Early PS360-series ovens Connections for pickup testG. Conveyor Control Pickup Test H. Conveyor Motor TestWiring for PS360 Shielded Pickup Cable - late terminal block design Wiring for PS360 Shielded Pickup Cable - early terminal block designK. Appendices SECTION 3 - SERVICING COMPONENTS Speed Controller Kit with Thumbwheel, P/N 42810-0133, 4/95SECTION 3 - SERVICING COMPONENTS Speed Controller Kit with Thumbwheel, P/N 42810-0133, 4/95Conveyor Speed Controller Kit with Thumbwheel, 4/95 Appendix - Instructions for Service KitSECTION 3 - SERVICING COMPONENTS Conveyor Speed Controller Kit with Thumbwheel, 4/95 Appendix - Instructions for Service KitSECTION 3 - SERVICING COMPONENTS Conveyor Speed Controller Kit with Thumbwheel, 4/95 Appendix - Instructions for Service KitSECTION 3 - SERVICING COMPONENTS Conveyor Speed Controller Kit with Thumbwheel, 4/95 Appendix - Instructions for Service KitSECTION 3 - SERVICING COMPONENTS Middleby Cooking Systems Group Service BulletinConveyor Speed Controller with Digital Display, P/N 37337, 8/00 SUBJECTConveyor Speed Controller Kit for PS200R68-series ovens Middleby Corporation Service Hotlinefor PS200R68-series Ovens, 2/02 Instructions for Service KitBrushes, and Pickup Clamps, 8/01 Appendix - Service Bulletin MM-189 - New Conveyor Gear MotorsService Bulletin Middleby Cooking Systems Groupwith Digital Display P/N 37337, 4/02 Appendix - DIP switch settings for Conveyor Speed ControllerII. TEMPERATURE CONTROLLER A. Part Number Reference - Temperature Controllers Figure 22 - Temperature controllers AB DEFGP/N 36056 G - Service Kit P/N P/N 46837 G - Service Kit P/NB. Description Appendix - Temperature controller terminal cross-reference, 4/02E. Appendices Instructions for Service Kit Digital Temperature ControllerInstallation, Programming and Troubleshooting Instructions Middleby Corporation Service HotlineController Types Before you Begin InstallationElectrical Connections Figure 5a Figure 4aFigure 5b Figure 4bProgramming Jumper SettingTemperature Controller Service InstructionsPage 7 of Page 8 of Diagnostic Error MessagesService Key Digital Temperature Controller P/N Operating InstructionsDisplay Unlock KeyMiddleby Cooking Systems Group 1400 Toastmaster Drive Elgin, IL Middleby Corporation Service Hotline847 741-3300 FAX 847 Filter Capacitor Assembly on Temperature Controllers, 9/93 Appendix - Service Bulletin MM-136 - Electrical NoiseSECTION 3 - SERVICING COMPONENTS Filter Capacitor Assembly on Temperature Controllers, 9/93 Appendix - Service Bulletin MM-136 - Electrical NoiseSECTION 3 - SERVICING COMPONENTS C. Operation and Troubleshooting Figure 23 - High limit control modules Shown in PS360-series ovenIII. HIGH LIMIT CONTROL MODULE A. Part Number Reference - High Limit Control Mod- ulesHigh Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 High Limit Conversion Kit for PS300, 310, 350, & 360 OvensAppendix - Instructions for Service Kit Instructions for Service KitB. INSTALLATION Appendix - Instructions for Service KitHigh Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 Page 2 ofHigh Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 Appendix - Instructions for Service KitNOT TO SCALE High limit thermocouple location lower ovenC. WIRING Appendix - Instructions for Service KitLighted Reset Switch Wiring and Installation Cooldown circuit wiringD. TESTING THE INSTALLATION Appendix - Instructions for Service KitHigh Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 Page 5 ofovens with a cooldown feature Appendix - Instructions for Service Kitreplacement High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99ovens without a cooldown feature Appendix - Instructions for Service Kitreplacement High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99Middleby Corporation Service Hotline Appendix - Instructions for Service KitHigh Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 A MIDDLEBY COMPANYTroubleshooting Figure 24 - ThermocouplesIV. THERMOCOUPLES A. Part Number Reference - ThermocouplesPage Instructions for Service Kits P/Ns 33984 and Oven Thermocouple KitKIT CONTENTS - KIT P/N KIT CONTENTS - KIT P/NOven Thermocouple Kit, 11/01 Appendix - Instructions for Service Kits 33984 andAnalog Temperature Controller Digital Temperature ControllerThermocouple Installation - PS360 Series Appendix - Instructions for Service Kits 33984 andThermocouple Wiring - PS360 Series Oven Thermocouple Kit, 11/01Analog Temperature Controller Appendix - Instructions for Service Kits 33984 andDigital Temperature Controller Oven Thermocouple Kit, 11/01Digital Temperature Controller Appendix - Instructions for Service Kits 33984 andOven Thermocouple Kit, 11/01 PS536Oven Thermocouple Kit, 11/01 Appendix - Instructions for Service Kits 33984 andNOTE FOR HIGH LIMIT THERMOCOUPLES 3. Disconnect the thermocouple leads. Refer to FigureOven Thermocouple Kit, 11/01 Appendix - Instructions for Service Kits 33984 andPS555 Electric and PS555E NOTE FOR HIGH LIMIT THERMOCOUPLESOven Thermocouple Kit, 11/01 Appendix - Instructions for Service Kits 33984 and3. Remove the rear shrouds. Open the blower motor com- partment doors Oven Thermocouple Kit, 11/01 Appendix - Instructions for Service Kits 33984 andHigh limit thermocouple position for ovens withOven Thermocouple Kit, 11/01 Appendix - Instructions for Service Kits 33984 andHigh limit thermocouple High limit thermocoupleOven Thermocouple Kit, 11/01 Appendix - Instructions for Service Kits 33984 andLeft RightThermocouple Wiring - PS555G and PS570G Appendix - Instructions for Service Kits 33984 andMiddleby Corporation Service Hotline Oven Thermocouple Kit, 11/01Current PS200 indirect drive assembly Early-style PS200 indirect drive assemblyBlower motor fuses V. BLOWERS A. PS200-series ovensBlower belt tension Bearing lubricationRepositioning the blower motor Loosen bolts to reposition motor and adjust belt tensionFan shaft alignment tool Description Part NumberNot available Not availableCord tied to shaft Figure 33 - Four-point alignment test for correct pulley alignmentCord must touch sheaves at four points indicated by arrows Part Number date early-style fan shaft assembly to the current version shown hereDescription Part NumberBlower motor fuses - three-phase motors Blower motor fuses - single-phase motorsB. PS360-series ovens Figure 37 - Clockwise blower wheel Figure 39 - Blower wheel placement Shown from rear of ovenFigure 38 - Counterclockwise blower wheel Inlet ringFigure 43 - PS555/570G blower configuration Figure 42 - PS570/570S blower configurationFigure 44 - Fuse/circuit breaker locations A. PS555/570-series ovensPart Number Part Number DescriptionDescription OvenBearing lubrication PS500-series blower wheel orientationFigure 48 - Four-point alignment test for correct pulley alignment Blower belt tension and repositioning the blower motorVI. BLOWER MOTOR CENTRIFUGAL SAFETY SWITCH PS360-SERIES Figure 49 - PS360-series blower motor centrifugal safety switchA. Part Number Reference - Blower Centrifugal Switch B. TroubleshootingDungs square-case “replacement” air switch with screw adjustment Figure 50 - Air pressure safety switch modelsPS360WB70/EWB with Wayne burner PS360WB70/EWB with Midco burnerB. Troubleshooting Connects to negative pressure side of air switchAir Pressure Switch Replacement Kits, 1/97 Appendix - Instructions for Service Kits 35624 andSECTION 3 - SERVICING COMPONENTS C. AppendicesAir Pressure Switch Replacement Kits, 1/97 Appendix - Instructions for Service Kits 35624 andSECTION 3 - SERVICING COMPONENTS P/N 36194 with Service Kit P/N 35624, 3/97 Appendix - Instructions to Replace an “Alternate” Air SwitchSECTION 3 - SERVICING COMPONENTS P/N 36194 with Service Kit P/N 35624, 3/97 Appendix - Instructions to Replace an “Alternate” Air SwitchSECTION 3 - SERVICING COMPONENTS Adjustment rod PS570/570S flame gate adjustmentIX. PS570/570S FLAME GATE A. Part Number Reference - Flame GatePS310, PS314, PS360 or PS360WB gas train PS200-series gas trainX. GAS TRAIN AND BURNER SYSTEM A. Part Number ReferencePS360EWB or PS360WB70 gas train with Wayne burner PS360EWB or PS360WB70 gas train with Midco burnerSWITCH SWITCHPS570G or PS555 gas train PS570S gas trainNOT SHOWN components are installed on back wall of machinery SWITCHB. Part Number Reference - Gas Orifices and Gas Conversion Kits Figure 60 - Wayne burner - exploded viewsame as natural gasFigure 62 - Wayne burner Figure 61 - Midco burnerC. Component Identification 1. Burner typeEnd of burner without flame target showing pilot shield Figure 63 - Pilot/ignitor assemblyFlame targets D. Pilot/Ignitor AssemblyFigure 67 - Flame rectification Figure 68 - Pilot and probe Flame structureFlame Rectification VoltageTemperature Air shutter adjustmentPilot Application Burner Blower MotorG. Burner Transformer Low Flame Bypass OrificeH. Burner Motor Relay I. High Flame Solenoid Valve if so equippedDigital Temperature Figure 71 - Modulating Gas SystemK. Modulating Gas Valve if so equipped L. Amplifier Board ovens with a modulating gas valve onlyBurrs in pilot adjustment portal Figure 72 - Combination Gas Control ValveM. Combination Gas Control Valve Pilot pressureN. Ignition Module O. Gas Conversion Kits P. Burner and Gas Train Troubleshooting1. Burner Blower Motor 3. Relay8. System Troubleshooting Voltage Checks for Ignition Module and Combination Gas Valve5. Burner Operation 6. Check Grounding10. Check Spark Ignition Circuit 9. Component Checks Reset System After Lockout11. Check Spark Ignitor Q. Checking the Gas PressuresSECTION 3 - SERVICING COMPONENTS R. Troubleshooting FlowchartsSECTION 3 - SERVICING COMPONENTS SECTION 3 - SERVICING COMPONENTS SECTION 3 - SERVICING COMPONENTS S. Appendices Appendix - Instructions for Service Kit Pilot/Ignitor Kit, 7/91SECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94SECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94SECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94SECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94SECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service Kit Combination Gas Valve, 1/92SECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service Kit Combination Gas Valve, 1/92SECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service Kit Combination Gas Valve, 1/92SECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service Kit Combination Gas Valve, 1/92SECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service Kit Ignition Module, 11/90SECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service Kit Ignition Module, 11/90during Burner Operation, 4/02 Appendix - Position of Combination Gas Valve ComponentsSECTION 3 - SERVICING COMPONENTS ENGLISH- page ESPAÑOL - página TORY BEFORE INSTALLING THIS KITPS360EWB all PS555 all PS570S units produced 4/00 or later KIT COMPONENTSAppendix - Instructions for All Gas Conversion Kits ENGLISHfor Ovens with Wayne Burner, Natural Gas to Propane, 8/00 Typical PS200-series gas train configurationII. COMBINATION GAS CONTROL VALVE SAFETY REGULATORCONVERSION I. PREPARATION AND DISASSEMBLYENGLISH Appendix - Instructions for All Gas Conversion KitsENGLISH VI. REASSEMBLYAppendix - Instructions for All Gas Conversion Kits for Ovens with Wayne Burner, Natural Gas to Propane, 8/00STAND WELL CLEAR WHEN SWITCHING ON IX. PILOT PRESSURE ADJUSTMENTRemove the pilot adjustment cap screw from the 4. If no leaks are detected by the test, depress the safetyAppendix - Instructions for All Gas Conversion Kits X. MANIFOLD PRESSURE ADJUSTMENTfor Ovens with Wayne Burner, Natural Gas to Propane, 8/00 XI. MARKING AND LABELINGKIT COMPONENTS ENGLISH- page ESPAÑOL - páginafor Ovens with Wayne Burner, Propane to Natural Gas, 8/00 Propane to Natural Gas OperationTypical PS200-series gas train configuration for Ovens with Wayne Burner, Propane to Natural Gas, 8/00Typical PS300-series gas train configuration Typical PS555 or PS570S gas train configurationII. COMBINATION GAS CONTROL VALVE SAFETY REGULATORCONVERSION I. PREPARATION AND DISASSEMBLYENGLISH Appendix - Instructions for All Gas Conversion KitsENGLISH VI. REASSEMBLYAppendix - Instructions for All Gas Conversion Kits for Ovens with Wayne Burner, Propane to Natural Gas, 8/00ENGLISH IX. PILOT PRESSURE ADJUSTMENTAppendix - Instructions for All Gas Conversion Kits for Ovens with Wayne Burner, Propane to Natural Gas, 8/00Appendix - Instructions for All Gas Conversion Kits X. MANIFOLD PRESSURE ADJUSTMENTfor Ovens with Wayne Burner, Propane to Natural Gas, 8/00 SECTION 3 - SERVICING COMPONENTSPS360EWB and PS360WB70 Middleby MarshallNatural Gas to Propane Installation Instructions 2. PILOT ORIFICE REPLACEMENT4. LOW FLAME ORIFICE REPLACEMENT PS360WB70 only 3. MAIN ORIFICE REPLACEMENTPilot orifice assembly Low flame orifice replacement8. MAIN MANIFOLD PRESSURE ADJUSTMENT 7. PILOT PRESSURE ADJUSTMENTGas pressure measurement/adjustment locations Burner blower configurationsConversion information label placement PS360EWB placement Red “LPG.” label placement on burner housingPS360WB70 placement 9. CONVERSION LABELING2. PILOT ORIFICE REPLACEMENT Propane to Natural Gas Installation InstructionsOrifice, Pilot Assembly - Natural Gas, 0.032” 0.81mm Middleby Marshall4. LOW FLAME ORIFICE REPLACEMENT PS360WB70 only 3. MAIN ORIFICE REPLACEMENTPilot orifice assembly Low flame orifice replacement8. MAIN MANIFOLD PRESSURE ADJUSTMENT 7. PILOT PRESSURE ADJUSTMENTGas pressure measurement/adjustment locations Burner blower configurations9. CONVERSION LABELING Yellow “NAT.” label placement on burner housingNATURAL 14” W.C./34.9mbarIncludes 4% reduction for each 1000 ft. above sea level, 4/02 Appendix - Equivalent Orifice Sizes at High AltitudesSECTION 3 - SERVICING COMPONENTS PS200 electric current with solid state PS200 electric early with mercury contactors and fusesrelays and circuit breaker blocks XI. ELECTRIC OVEN HEATING SYSTEM A. PS200-series ovensIndividual element electrical data Removing elementsRemoving the element bank mounting bolts Electrical leads disconnectedB. PS310/360-series ovens Part No. DescriptionIndividual element electrical data Element bank removed - spacer bracket visible107W Spacer bracketsHeating element assembly Refer to Temperature Controller on PageHeating element assembly Heating element assemblycover PS555 electric oven heating element removalD. Mercury Contactor Replacement Place a deep well socket over the new Tinnerman clip SECTION 3 - SERVICING COMPONENTS I. COMPONENT WIRING SECTION ELECTRICAL WIRING DIAGRAMSSECTION 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 groundSECTION 4 - ELECTRICAL WIRING DIAGRAMS 208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground PAGE 1 OFSECTION 4 - ELECTRICAL WIRING DIAGRAMS 208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground PAGE 2 OFSECTION 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 groundDIAGRAMS SECTION 4 - ELECTRICAL WIRINGIII. 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 groundSECTION 4 - ELECTRICAL WIRING DIAGRAMS 208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 groundSECTION 4 - ELECTRICAL WIRING DIAGRAMS 208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 groundSECTION 4 - ELECTRICAL WIRING DIAGRAMS DIAGRAMS SECTION 4 - ELECTRICAL WIRINGIII. PS555/570-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 PS555 gas oven early, 208/240V main blower motor and control circuitSECTION 4 - ELECTRICAL WIRING DIAGRAMS SECTION 4 - ELECTRICAL WIRING DIAGRAMS 208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 groundSECTION 4 - ELECTRICAL WIRING DIAGRAMS 208/240V, 50/60 Hz, 3 Ph, 3 pole, 4 wire supply 3 hot, 1 groundSECTION 25-point preventative maintenance checklistREFERENCE Decimal equivalents of drill sizes Fractional inches to decimal and millimeter equivalentsSECTION 5 - REFERENCE Pressure conversions General conversion factorsMULTIPLY TO OBTAINOhm’s Law equation wheel Pressure conversion chartSECTION 5 - REFERENCE Common electrical wiring diagram symbolsSECTION 5 - REFERENCE Common electrical wiring diagram symbols continuedSECTION 5 - REFERENCE Common electrical wiring diagram symbols continuedSECTION 5 - REFERENCE Common electrical wiring diagram symbols continued2002 Middleby Marshall, Inc Commercial Food Equipment Service Association CFESAMiddleby is proud to support the