Manuals / Middleby Marshall / Kitchen Appliance / Double Oven

Middleby Marshall PS200, PS570 manual Appendix - Instructions for Service Kit, Servicing Components

Models: PS224 PS310 PS220 PS555 PS200 PS360 PS570

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SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 42810-0133-

Conveyor Speed Controller Kit with Thumbwheel, 4/95

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Middleby Marshall PS200 manual Appendix - Instructions for Service Kit, Conveyor Speed Controller Kit with Thumbwheel, 4/95

Contents

Page technical service manual PS200/220/224 Series PS310/360 Series PS555/570 Series2002 Middleby Marshall, Inc This Technical Service Manual includes informationTABLE OF CONTENTS DISCONNECT THE OVEN FROM ITS ELECTRICAL POWER SUPPLY BEFORE SERVICINGInstructions for Service Kits 33984 and TABLE OF CONTENTS continuedInstructions for Service Kit Blower Motor Centrifugal Safety Switch PS360-seriesSECTION SEQUENCE OF OPERATION I. GAS OVEN SEQUENCE OF OPERATIONNOTE PS200VL-series ovens do not include a cooldown feature SECTION 1 - SEQUENCE OF OPERATION F. High LimitNOTE Electric oven models use a separate High Limit Control Module I. TYPES OF HEAT TRANSFER SECTION AIR FLOW AND HEAT TRANSFERBlowers, belts and pulleys II. BLOWERS AND BLOWER SPEEDCurrent standard air finger all oven models Air finger operationPS300/350 air finger with shutter plate B. PS360-series ovensB. Configuration and Alignment 3D air finger label if presentInternal air finger chart C. Performing a Test BakeFront-to-back uneven bake D. PS300/350 Air Finger Shutter AdjustmentPS300/350-style air finger with adjustable shutter plate Figure 10 - Belt Time Figure 9 - Conveyor Speed Bake TimeFigure 11 - Time of Delivery IV. OVEN CAPACITYCurrent-style speed controller SECTION SERVICING COMPONENTSOriginal-style speed controller 4 or 8 DIP switches select oven model2. Current-style pickup assembly see Figures PS350-style pickup assembly used on early PS360Old-style pickup assembly C. Preparing to Service the Speed ControllerField Tester for Conveyor Drive Motor Current pickup assembly - side viewCurrent pickup assembly end view D. Controller/Motor Failure1. IF THE GEAR MOTOR RUNS AT FULL SPEED E. Basic Troubleshooting FlowchartsMiddleby no longer stocks parts for the 2. IF THE GEAR MOTOR WILL NOT RUN AT ALLSECTION 3 - SERVICING COMPONENTS with a current modelConnections are reversed if conveyor direc- tion is reversed F. Initial Troubleshooting120VAC supply. Wire colors vary by oven model G. Conveyor Control Pickup Test Connections for pickup testJ. Unshielded Pickup Wires on Early PS360-series ovens H. Conveyor Motor TestK. Appendices Wiring for PS360 Shielded Pickup Cable - early terminal block designWiring for PS360 Shielded Pickup Cable - late terminal block design Speed Controller Kit with Thumbwheel, P/N 42810-0133, 4/95 SECTION 3 - SERVICING COMPONENTSSpeed Controller Kit with Thumbwheel, P/N 42810-0133, 4/95 SECTION 3 - SERVICING COMPONENTSSECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service KitConveyor Speed Controller Kit with Thumbwheel, 4/95 SECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service KitConveyor Speed Controller Kit with Thumbwheel, 4/95 SECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service KitConveyor Speed Controller Kit with Thumbwheel, 4/95 SECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service KitConveyor Speed Controller Kit with Thumbwheel, 4/95 Conveyor Speed Controller with Digital Display, P/N 37337, 8/00 Service BulletinMiddleby Cooking Systems Group SUBJECTfor PS200R68-series Ovens, 2/02 Middleby Corporation Service HotlineConveyor Speed Controller Kit for PS200R68-series ovens Instructions for Service KitService Bulletin Appendix - Service Bulletin MM-189 - New Conveyor Gear MotorsBrushes, and Pickup Clamps, 8/01 Middleby Cooking Systems GroupII. TEMPERATURE CONTROLLER Appendix - DIP switch settings for Conveyor Speed Controllerwith Digital Display P/N 37337, 4/02 P/N 46837 G - Service Kit P/N Figure 22 - Temperature controllers AB DEFGP/N 36056 G - Service Kit P/N A. Part Number Reference - Temperature ControllersE. Appendices Appendix - Temperature controller terminal cross-reference, 4/02B. Description Digital Temperature Controller Instructions for Service KitInstallation, Programming and Troubleshooting Instructions Middleby Corporation Service HotlineController Types Installation Before you BeginElectrical Connections Figure 5b Figure 4aFigure 5a Figure 4bJumper Setting ProgrammingPage 7 of Controller Service InstructionsTemperature Diagnostic Error Messages Page 8 ofDisplay Digital Temperature Controller P/N Operating InstructionsService Key Unlock Key847 741-3300 FAX 847 Middleby Corporation Service HotlineMiddleby Cooking Systems Group 1400 Toastmaster Drive Elgin, IL SECTION 3 - SERVICING COMPONENTS Appendix - Service Bulletin MM-136 - Electrical NoiseFilter Capacitor Assembly on Temperature Controllers, 9/93 SECTION 3 - SERVICING COMPONENTS Appendix - Service Bulletin MM-136 - Electrical NoiseFilter Capacitor Assembly on Temperature Controllers, 9/93 III. HIGH LIMIT CONTROL MODULE Figure 23 - High limit control modules Shown in PS360-series ovenC. Operation and Troubleshooting A. Part Number Reference - High Limit Control Mod- ulesAppendix - Instructions for Service Kit High Limit Conversion Kit for PS300, 310, 350, & 360 OvensHigh Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 Instructions for Service KitHigh Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 Appendix - Instructions for Service KitB. INSTALLATION Page 2 ofNOT TO SCALE Appendix - Instructions for Service KitHigh Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 High limit thermocouple location lower ovenLighted Reset Switch Wiring and Installation Appendix - Instructions for Service KitC. WIRING Cooldown circuit wiringHigh Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 Appendix - Instructions for Service KitD. TESTING THE INSTALLATION Page 5 ofreplacement Appendix - Instructions for Service Kitovens with a cooldown feature High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99replacement Appendix - Instructions for Service Kitovens without a cooldown feature High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 Appendix - Instructions for Service KitMiddleby Corporation Service Hotline A MIDDLEBY COMPANYIV. THERMOCOUPLES Figure 24 - ThermocouplesTroubleshooting A. Part Number Reference - ThermocouplesPage KIT CONTENTS - KIT P/N Oven Thermocouple KitInstructions for Service Kits P/Ns 33984 and KIT CONTENTS - KIT P/NPS200 Series - before 2/96, serial numbers before ASH-0001 Appendix - Instructions for Service Kits 33984 andOven Thermocouple Kit, 11/01 PS200 Series - 2/96 or later, serial numbers after ASH-0001Thermocouple Wiring - PS360 Series Appendix - Instructions for Service Kits 33984 andThermocouple Installation - PS360 Series Oven Thermocouple Kit, 11/01Analog Temperature Controller Appendix - Instructions for Service Kits 33984 andOven Thermocouple Kit, 11/01 Digital Temperature ControllerPS536 Appendix - Instructions for Service Kits 33984 andOven Thermocouple Kit, 11/01 NOTE FOR HIGH LIMIT THERMOCOUPLESNOTE FOR HIGH LIMIT THERMOCOUPLES Appendix - Instructions for Service Kits 33984 andOven Thermocouple Kit, 11/01 3. Disconnect the thermocouple leads. Refer to FigurePS555 Electric and PS555E Appendix - Instructions for Service Kits 33984 andOven Thermocouple Kit, 11/01 NOTE FOR HIGH LIMIT THERMOCOUPLES3. Remove the rear shrouds. Open the blower motor com- partment doors Appendix - Instructions for Service Kits 33984 andOven Thermocouple Kit, 11/01 High limit thermocouple Appendix - Instructions for Service Kits 33984 andOven Thermocouple Kit, 11/01 position for ovens withHigh limit thermocouple Appendix - Instructions for Service Kits 33984 andOven Thermocouple Kit, 11/01 High limit thermocoupleLeft Appendix - Instructions for Service Kits 33984 andOven Thermocouple Kit, 11/01 RightMiddleby Corporation Service Hotline Appendix - Instructions for Service Kits 33984 andThermocouple Wiring - PS555G and PS570G Oven Thermocouple Kit, 11/01Blower motor fuses Early-style PS200 indirect drive assemblyCurrent PS200 indirect drive assembly V. BLOWERS A. PS200-series ovensRepositioning the blower motor Bearing lubricationBlower belt tension Loosen bolts to reposition motor and adjust belt tensionFan shaft alignment tool Not available Part NumberDescription Not availableCord must touch sheaves at four points indicated by arrows Figure 33 - Four-point alignment test for correct pulley alignmentCord tied to shaft Description date early-style fan shaft assembly to the current version shown herePart Number Part NumberB. PS360-series ovens Blower motor fuses - single-phase motorsBlower motor fuses - three-phase motors Figure 38 - Counterclockwise blower wheel Figure 39 - Blower wheel placement Shown from rear of ovenFigure 37 - Clockwise blower wheel Inlet ringFigure 44 - Fuse/circuit breaker locations Figure 42 - PS570/570S blower configurationFigure 43 - PS555/570G blower configuration A. PS555/570-series ovensDescription Part Number DescriptionPart Number OvenPS500-series blower wheel orientation Bearing lubricationBlower belt tension and repositioning the blower motor Figure 48 - Four-point alignment test for correct pulley alignmentA. Part Number Reference - Blower Centrifugal Switch Figure 49 - PS360-series blower motor centrifugal safety switchVI. BLOWER MOTOR CENTRIFUGAL SAFETY SWITCH PS360-SERIES B. TroubleshootingFigure 50 - Air pressure safety switch models Dungs square-case “replacement” air switch with screw adjustmentB. Troubleshooting PS360WB70/EWB with Midco burnerPS360WB70/EWB with Wayne burner Connects to negative pressure side of air switchSECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service Kits 35624 andAir Pressure Switch Replacement Kits, 1/97 C. AppendicesSECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service Kits 35624 andAir Pressure Switch Replacement Kits, 1/97 SECTION 3 - SERVICING COMPONENTS Appendix - Instructions to Replace an “Alternate” Air SwitchP/N 36194 with Service Kit P/N 35624, 3/97 SECTION 3 - SERVICING COMPONENTS Appendix - Instructions to Replace an “Alternate” Air SwitchP/N 36194 with Service Kit P/N 35624, 3/97 IX. PS570/570S FLAME GATE PS570/570S flame gate adjustmentAdjustment rod A. Part Number Reference - Flame GateX. GAS TRAIN AND BURNER SYSTEM PS200-series gas trainPS310, PS314, PS360 or PS360WB gas train A. Part Number ReferenceSWITCH PS360EWB or PS360WB70 gas train with Midco burnerPS360EWB or PS360WB70 gas train with Wayne burner SWITCHNOT SHOWN components are installed on back wall of machinery PS570S gas trainPS570G or PS555 gas train SWITCHsame as Figure 60 - Wayne burner - exploded viewB. Part Number Reference - Gas Orifices and Gas Conversion Kits natural gasC. Component Identification Figure 61 - Midco burnerFigure 62 - Wayne burner 1. Burner typeFlame targets Figure 63 - Pilot/ignitor assemblyEnd of burner without flame target showing pilot shield D. Pilot/Ignitor AssemblyFlame Rectification Flame structureFigure 67 - Flame rectification Figure 68 - Pilot and probe VoltagePilot Application Air shutter adjustmentTemperature Burner Blower MotorH. Burner Motor Relay Low Flame Bypass OrificeG. Burner Transformer I. High Flame Solenoid Valve if so equippedL. Amplifier Board ovens with a modulating gas valve only Figure 71 - Modulating Gas SystemK. Modulating Gas Valve if so equipped Digital TemperatureM. Combination Gas Control Valve Figure 72 - Combination Gas Control ValveBurrs in pilot adjustment portal Pilot pressureN. Ignition Module 1. Burner Blower Motor P. Burner and Gas Train TroubleshootingO. Gas Conversion Kits 3. Relay5. Burner Operation Voltage Checks for Ignition Module and Combination Gas Valve8. System Troubleshooting 6. Check Grounding11. Check Spark Ignitor 9. Component Checks Reset System After Lockout10. Check Spark Ignition Circuit Q. Checking the Gas PressuresR. Troubleshooting Flowcharts SECTION 3 - SERVICING COMPONENTSSECTION 3 - SERVICING COMPONENTS SECTION 3 - SERVICING COMPONENTS SECTION 3 - SERVICING COMPONENTS Appendix - Instructions for Service Kit Pilot/Ignitor Kit, 7/91 S. AppendicesAppendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94 SECTION 3 - SERVICING COMPONENTSAppendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94 SECTION 3 - SERVICING COMPONENTSAppendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94 SECTION 3 - SERVICING COMPONENTSAppendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94 SECTION 3 - SERVICING COMPONENTSAppendix - Instructions for Service Kit Combination Gas Valve, 1/92 SECTION 3 - SERVICING COMPONENTSAppendix - Instructions for Service Kit Combination Gas Valve, 1/92 SECTION 3 - SERVICING COMPONENTSAppendix - Instructions for Service Kit Combination Gas Valve, 1/92 SECTION 3 - SERVICING COMPONENTSAppendix - Instructions for Service Kit Combination Gas Valve, 1/92 SECTION 3 - SERVICING COMPONENTSAppendix - Instructions for Service Kit Ignition Module, 11/90 SECTION 3 - SERVICING COMPONENTSAppendix - Instructions for Service Kit Ignition Module, 11/90 SECTION 3 - SERVICING COMPONENTSSECTION 3 - SERVICING COMPONENTS Appendix - Position of Combination Gas Valve Componentsduring Burner Operation, 4/02 PS360EWB all PS555 all PS570S units produced 4/00 or later TORY BEFORE INSTALLING THIS KITENGLISH- page ESPAÑOL - página KIT COMPONENTSfor Ovens with Wayne Burner, Natural Gas to Propane, 8/00 ENGLISHAppendix - Instructions for All Gas Conversion Kits Typical PS200-series gas train configurationENGLISH I. PREPARATION AND DISASSEMBLYII. COMBINATION GAS CONTROL VALVE SAFETY REGULATORCONVERSION Appendix - Instructions for All Gas Conversion KitsAppendix - Instructions for All Gas Conversion Kits VI. REASSEMBLYENGLISH for Ovens with Wayne Burner, Natural Gas to Propane, 8/00Remove the pilot adjustment cap screw from the IX. PILOT PRESSURE ADJUSTMENTSTAND WELL CLEAR WHEN SWITCHING ON 4. If no leaks are detected by the test, depress the safetyfor Ovens with Wayne Burner, Natural Gas to Propane, 8/00 X. MANIFOLD PRESSURE ADJUSTMENTAppendix - Instructions for All Gas Conversion Kits XI. MARKING AND LABELINGfor Ovens with Wayne Burner, Propane to Natural Gas, 8/00 ENGLISH- page ESPAÑOL - páginaKIT COMPONENTS Propane to Natural Gas OperationTypical PS300-series gas train configuration for Ovens with Wayne Burner, Propane to Natural Gas, 8/00Typical PS200-series gas train configuration Typical PS555 or PS570S gas train configurationENGLISH I. PREPARATION AND DISASSEMBLYII. COMBINATION GAS CONTROL VALVE SAFETY REGULATORCONVERSION Appendix - Instructions for All Gas Conversion KitsAppendix - Instructions for All Gas Conversion Kits VI. REASSEMBLYENGLISH for Ovens with Wayne Burner, Propane to Natural Gas, 8/00Appendix - Instructions for All Gas Conversion Kits IX. PILOT PRESSURE ADJUSTMENTENGLISH for Ovens with Wayne Burner, Propane to Natural Gas, 8/00for Ovens with Wayne Burner, Propane to Natural Gas, 8/00 X. MANIFOLD PRESSURE ADJUSTMENTAppendix - Instructions for All Gas Conversion Kits SECTION 3 - SERVICING COMPONENTSNatural Gas to Propane Installation Instructions Middleby MarshallPS360EWB and PS360WB70 2. PILOT ORIFICE REPLACEMENTPilot orifice assembly 3. MAIN ORIFICE REPLACEMENT4. LOW FLAME ORIFICE REPLACEMENT PS360WB70 only Low flame orifice replacementGas pressure measurement/adjustment locations 7. PILOT PRESSURE ADJUSTMENT8. MAIN MANIFOLD PRESSURE ADJUSTMENT Burner blower configurationsPS360WB70 placement Red “LPG.” label placement on burner housingConversion information label placement PS360EWB placement 9. CONVERSION LABELINGOrifice, Pilot Assembly - Natural Gas, 0.032” 0.81mm Propane to Natural Gas Installation Instructions2. PILOT ORIFICE REPLACEMENT Middleby MarshallPilot orifice assembly 3. MAIN ORIFICE REPLACEMENT4. LOW FLAME ORIFICE REPLACEMENT PS360WB70 only Low flame orifice replacementGas pressure measurement/adjustment locations 7. PILOT PRESSURE ADJUSTMENT8. MAIN MANIFOLD PRESSURE ADJUSTMENT Burner blower configurationsNATURAL Yellow “NAT.” label placement on burner housing9. CONVERSION LABELING 14” W.C./34.9mbarSECTION 3 - SERVICING COMPONENTS Appendix - Equivalent Orifice Sizes at High AltitudesIncludes 4% reduction for each 1000 ft. above sea level, 4/02 relays and circuit breaker blocks PS200 electric early with mercury contactors and fusesPS200 electric current with solid state XI. ELECTRIC OVEN HEATING SYSTEM A. PS200-series ovensRemoving elements Individual element electrical dataB. PS310/360-series ovens Electrical leads disconnectedRemoving the element bank mounting bolts Part No. Description107W Element bank removed - spacer bracket visibleIndividual element electrical data Spacer bracketsHeating element assembly Heating element assemblyHeating element assembly Heating element assemblyPS555 electric oven heating element removal coverD. Mercury Contactor Replacement Place a deep well socket over the new Tinnerman clip SECTION 3 - SERVICING COMPONENTS SECTION ELECTRICAL WIRING DIAGRAMS I. COMPONENT WIRINGSECTION 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 DIAGRAMSSECTION 4 - ELECTRICAL WIRING DIAGRAMS SECTION 4 - ELECTRICAL WIRING DIAGRAMS PAGE 1 OF208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground SECTION 4 - ELECTRICAL WIRING DIAGRAMS PAGE 2 OF208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground 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 DIAGRAMSIII. PS360-SERIES OVENS SECTION 4 - ELECTRICAL WIRINGDIAGRAMS 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 DIAGRAMS208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground SECTION 4 - ELECTRICAL WIRING DIAGRAMS208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground SECTION 4 - ELECTRICAL WIRING DIAGRAMSSECTION 4 - ELECTRICAL WIRING DIAGRAMS III. PS555/570-SERIES OVENS SECTION 4 - ELECTRICAL WIRINGDIAGRAMS SECTION 4 - ELECTRICAL WIRING DIAGRAMS SECTION 4 - ELECTRICAL WIRING DIAGRAMS SECTION 4 - ELECTRICAL WIRING DIAGRAMS PS555 gas oven early, 208/240V main blower motor and control circuit208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground 208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply 2 hot, 1 ground SECTION 4 - ELECTRICAL WIRING DIAGRAMS208/240V, 50/60 Hz, 3 Ph, 3 pole, 4 wire supply 3 hot, 1 ground SECTION 4 - ELECTRICAL WIRING DIAGRAMSREFERENCE 25-point preventative maintenance checklistSECTION SECTION 5 - REFERENCE Fractional inches to decimal and millimeter equivalentsDecimal equivalents of drill sizes MULTIPLY General conversion factorsPressure conversions TO OBTAINPressure conversion chart Ohm’s Law equation wheelCommon electrical wiring diagram symbols SECTION 5 - REFERENCECommon electrical wiring diagram symbols continued SECTION 5 - REFERENCECommon electrical wiring diagram symbols continued SECTION 5 - REFERENCECommon electrical wiring diagram symbols continued SECTION 5 - REFERENCEMiddleby is proud to support the Commercial Food Equipment Service Association CFESA2002 Middleby Marshall, Inc