Manuals / Middleby Marshall / Kitchen Appliance / Double Oven

Middleby Marshall PS360, PS570, PS200 Middleby Corporation Service Hotline, 847 741-3300 FAX 847

Models: PS224 PS310 PS220 PS555 PS200 PS360 PS570

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SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 47321 - Digital Temperature Controller Kit, 2/02

Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120

(847) 741-3300 • FAX (847) 741-4406

Middleby Corporation Service Hotline 1-800-238-8444

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Middleby Marshall PS360, PS570, PS200, PS555, PS220, PS224 PS310 Middleby Corporation Service Hotline, 847 741-3300 FAX 847

Contents

Page This Technical Service Manual includes information PS200/220/224 Series PS310/360 Series PS555/570 Series2002 Middleby Marshall, Inc technical service manualDISCONNECT THE OVEN FROM ITS ELECTRICAL POWER SUPPLY BEFORE SERVICING TABLE OF CONTENTSBlower Motor Centrifugal Safety Switch PS360-series TABLE OF CONTENTS continuedInstructions for Service Kit Instructions for Service Kits 33984 andI. 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 II. BLOWERS AND BLOWER SPEED SECTION AIR FLOW AND HEAT TRANSFERBlowers, belts and pulleys I. TYPES OF HEAT TRANSFERB. PS360-series ovens Air finger operationPS300/350 air finger with shutter plate Current standard air finger all oven modelsC. Performing a Test Bake 3D air finger label if presentInternal air finger chart B. Configuration and AlignmentD. PS300/350 Air Finger Shutter Adjustment Front-to-back uneven bakePS300/350-style air finger with adjustable shutter plate IV. OVEN CAPACITY Figure 9 - Conveyor Speed Bake TimeFigure 11 - Time of Delivery Figure 10 - Belt Time4 or 8 DIP switches select oven model SECTION SERVICING COMPONENTSOriginal-style speed controller Current-style speed controllerC. Preparing to Service the Speed Controller PS350-style pickup assembly used on early PS360Old-style pickup assembly 2. Current-style pickup assembly see FiguresD. Controller/Motor Failure Current pickup assembly - side viewCurrent pickup assembly end view Field Tester for Conveyor Drive MotorE. Basic Troubleshooting Flowcharts 1. IF THE GEAR MOTOR RUNS AT FULL SPEEDwith a current model 2. IF THE GEAR MOTOR WILL NOT RUN AT ALLSECTION 3 - SERVICING COMPONENTS Middleby no longer stocks parts for the120VAC supply. Wire colors vary by oven model F. Initial TroubleshootingConnections are reversed if conveyor direc- tion is reversed H. Conveyor Motor Test Connections for pickup testJ. Unshielded Pickup Wires on Early PS360-series ovens G. Conveyor Control Pickup 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 SUBJECT Service BulletinMiddleby Cooking Systems Group Conveyor Speed Controller with Digital Display, P/N 37337, 8/00Instructions for Service Kit Middleby Corporation Service HotlineConveyor Speed Controller Kit for PS200R68-series ovens for PS200R68-series Ovens, 2/02Middleby Cooking Systems Group Appendix - Service Bulletin MM-189 - New Conveyor Gear MotorsBrushes, and Pickup Clamps, 8/01 Service Bulletinwith Digital Display P/N 37337, 4/02 Appendix - DIP switch settings for Conveyor Speed ControllerII. TEMPERATURE CONTROLLER P/N 46837 G - Service Kit P/N Figure 22 - Temperature controllers AB DEFGA. Part Number Reference - Temperature Controllers P/N 36056 G - Service Kit P/NB. Description Appendix - Temperature controller terminal cross-reference, 4/02E. Appendices Middleby Corporation Service Hotline Digital Temperature ControllerInstructions for Service Kit Installation, Programming and Troubleshooting InstructionsController Types Before you Begin InstallationElectrical Connections Figure 4b Figure 4aFigure 5a Figure 5bProgramming Jumper SettingTemperature Controller Service InstructionsPage 7 of Page 8 of Diagnostic Error MessagesUnlock Key Digital Temperature Controller P/N Operating InstructionsService Key DisplayMiddleby 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 A. Part Number Reference - High Limit Control Mod- ules Figure 23 - High limit control modules Shown in PS360-series ovenC. Operation and Troubleshooting III. HIGH LIMIT CONTROL MODULEInstructions for Service Kit High Limit Conversion Kit for PS300, 310, 350, & 360 OvensHigh Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 Appendix - Instructions for Service KitPage 2 of Appendix - Instructions for Service KitB. INSTALLATION High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99High limit thermocouple location lower oven Appendix - Instructions for Service KitHigh Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 NOT TO SCALECooldown circuit wiring Appendix - Instructions for Service KitC. WIRING Lighted Reset Switch Wiring and InstallationPage 5 of Appendix - Instructions for Service KitD. TESTING THE INSTALLATION 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 Kitovens with a cooldown feature replacementHigh Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 Appendix - Instructions for Service Kitovens without a cooldown feature replacementA MIDDLEBY COMPANY Appendix - Instructions for Service KitMiddleby Corporation Service Hotline High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99A. Part Number Reference - Thermocouples Figure 24 - ThermocouplesTroubleshooting IV. THERMOCOUPLESPage KIT CONTENTS - KIT P/N Oven Thermocouple KitInstructions for Service Kits P/Ns 33984 and KIT CONTENTS - KIT P/NDigital Temperature Controller Appendix - Instructions for Service Kits 33984 andOven Thermocouple Kit, 11/01 Analog Temperature ControllerOven Thermocouple Kit, 11/01 Appendix - Instructions for Service Kits 33984 andThermocouple Installation - PS360 Series Thermocouple Wiring - PS360 SeriesOven Thermocouple Kit, 11/01 Appendix - Instructions for Service Kits 33984 andAnalog Temperature Controller Digital Temperature ControllerPS536 Appendix - Instructions for Service Kits 33984 andDigital Temperature Controller Oven Thermocouple Kit, 11/013. Disconnect the thermocouple leads. Refer to Figure 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 PS555 Electric and PS555EOven Thermocouple Kit, 11/01 Appendix - Instructions for Service Kits 33984 and3. Remove the rear shrouds. Open the blower motor com- partment doors position for ovens with Appendix - Instructions for Service Kits 33984 andOven Thermocouple Kit, 11/01 High limit thermocoupleHigh limit thermocouple Appendix - Instructions for Service Kits 33984 andOven Thermocouple Kit, 11/01 High limit thermocoupleRight Appendix - Instructions for Service Kits 33984 andOven Thermocouple Kit, 11/01 LeftOven Thermocouple Kit, 11/01 Appendix - Instructions for Service Kits 33984 andThermocouple Wiring - PS555G and PS570G Middleby Corporation Service HotlineV. BLOWERS A. PS200-series ovens Early-style PS200 indirect drive assemblyCurrent PS200 indirect drive assembly Blower motor fusesLoosen bolts to reposition motor and adjust belt tension Bearing lubricationBlower belt tension Repositioning the blower motorFan shaft alignment tool Not available Part NumberDescription 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 herePart Number DescriptionBlower motor fuses - three-phase motors Blower motor fuses - single-phase motorsB. PS360-series ovens Inlet ring Figure 39 - Blower wheel placement Shown from rear of ovenFigure 37 - Clockwise blower wheel Figure 38 - Counterclockwise blower wheelA. PS555/570-series ovens Figure 42 - PS570/570S blower configurationFigure 43 - PS555/570G blower configuration Figure 44 - Fuse/circuit breaker locationsOven Part Number DescriptionPart Number DescriptionBearing lubrication PS500-series blower wheel orientationFigure 48 - Four-point alignment test for correct pulley alignment Blower belt tension and repositioning the blower motorB. Troubleshooting Figure 49 - PS360-series blower motor centrifugal safety switchVI. BLOWER MOTOR CENTRIFUGAL SAFETY SWITCH PS360-SERIES A. Part Number Reference - Blower Centrifugal SwitchDungs square-case “replacement” air switch with screw adjustment Figure 50 - Air pressure safety switch modelsConnects to negative pressure side of air switch PS360WB70/EWB with Midco burnerPS360WB70/EWB with Wayne burner B. TroubleshootingC. Appendices Appendix - Instructions for Service Kits 35624 andAir Pressure Switch Replacement Kits, 1/97 SECTION 3 - SERVICING COMPONENTSAir 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 A. Part Number Reference - Flame Gate PS570/570S flame gate adjustmentAdjustment rod IX. PS570/570S FLAME GATEA. Part Number Reference PS200-series gas trainPS310, PS314, PS360 or PS360WB gas train X. GAS TRAIN AND BURNER SYSTEMSWITCH PS360EWB or PS360WB70 gas train with Midco burnerPS360EWB or PS360WB70 gas train with Wayne burner SWITCHSWITCH PS570S gas trainPS570G or PS555 gas train NOT SHOWN components are installed on back wall of machinerynatural gas Figure 60 - Wayne burner - exploded viewB. Part Number Reference - Gas Orifices and Gas Conversion Kits same as1. Burner type Figure 61 - Midco burnerFigure 62 - Wayne burner C. Component IdentificationD. Pilot/Ignitor Assembly Figure 63 - Pilot/ignitor assemblyEnd of burner without flame target showing pilot shield Flame targetsVoltage Flame structureFigure 67 - Flame rectification Figure 68 - Pilot and probe Flame RectificationBurner Blower Motor Air shutter adjustmentTemperature Pilot ApplicationI. High Flame Solenoid Valve if so equipped Low Flame Bypass OrificeG. Burner Transformer H. Burner Motor RelayL. Amplifier Board ovens with a modulating gas valve only Figure 71 - Modulating Gas SystemDigital Temperature K. Modulating Gas Valve if so equippedPilot pressure Figure 72 - Combination Gas Control ValveBurrs in pilot adjustment portal M. Combination Gas Control ValveN. Ignition Module 3. Relay P. Burner and Gas Train TroubleshootingO. Gas Conversion Kits 1. Burner Blower Motor6. Check Grounding Voltage Checks for Ignition Module and Combination Gas Valve8. System Troubleshooting 5. Burner OperationQ. Checking the Gas Pressures 9. Component Checks Reset System After Lockout10. Check Spark Ignition Circuit 11. Check Spark IgnitorSECTION 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 KIT COMPONENTS TORY BEFORE INSTALLING THIS KITENGLISH- page ESPAÑOL - página PS360EWB all PS555 all PS570S units produced 4/00 or laterTypical PS200-series gas train configuration ENGLISHAppendix - Instructions for All Gas Conversion Kits for Ovens with Wayne Burner, Natural Gas to Propane, 8/00Appendix - Instructions for All Gas Conversion Kits I. PREPARATION AND DISASSEMBLYII. COMBINATION GAS CONTROL VALVE SAFETY REGULATORCONVERSION ENGLISHfor Ovens with Wayne Burner, Natural Gas to Propane, 8/00 VI. REASSEMBLYENGLISH Appendix - Instructions for All Gas Conversion Kits4. If no leaks are detected by the test, depress the safety IX. PILOT PRESSURE ADJUSTMENTSTAND WELL CLEAR WHEN SWITCHING ON Remove the pilot adjustment cap screw from theXI. MARKING AND LABELING X. MANIFOLD PRESSURE ADJUSTMENTAppendix - Instructions for All Gas Conversion Kits for Ovens with Wayne Burner, Natural Gas to Propane, 8/00Propane to Natural Gas Operation ENGLISH- page ESPAÑOL - páginaKIT COMPONENTS for Ovens with Wayne Burner, Propane to Natural Gas, 8/00Typical PS555 or PS570S gas train configuration for Ovens with Wayne Burner, Propane to Natural Gas, 8/00Typical PS200-series gas train configuration Typical PS300-series gas train configurationAppendix - Instructions for All Gas Conversion Kits I. PREPARATION AND DISASSEMBLYII. COMBINATION GAS CONTROL VALVE SAFETY REGULATORCONVERSION ENGLISHfor Ovens with Wayne Burner, Propane to Natural Gas, 8/00 VI. REASSEMBLYENGLISH Appendix - Instructions for All Gas Conversion Kitsfor Ovens with Wayne Burner, Propane to Natural Gas, 8/00 IX. PILOT PRESSURE ADJUSTMENTENGLISH Appendix - Instructions for All Gas Conversion KitsSECTION 3 - SERVICING COMPONENTS X. MANIFOLD PRESSURE ADJUSTMENTAppendix - Instructions for All Gas Conversion Kits for Ovens with Wayne Burner, Propane to Natural Gas, 8/002. PILOT ORIFICE REPLACEMENT Middleby MarshallPS360EWB and PS360WB70 Natural Gas to Propane Installation InstructionsLow flame orifice replacement 3. MAIN ORIFICE REPLACEMENT4. LOW FLAME ORIFICE REPLACEMENT PS360WB70 only Pilot orifice assemblyBurner blower configurations 7. PILOT PRESSURE ADJUSTMENT8. MAIN MANIFOLD PRESSURE ADJUSTMENT Gas pressure measurement/adjustment locations9. CONVERSION LABELING Red “LPG.” label placement on burner housingConversion information label placement PS360EWB placement PS360WB70 placementMiddleby Marshall Propane to Natural Gas Installation Instructions2. PILOT ORIFICE REPLACEMENT Orifice, Pilot Assembly - Natural Gas, 0.032” 0.81mmLow flame orifice replacement 3. MAIN ORIFICE REPLACEMENT4. LOW FLAME ORIFICE REPLACEMENT PS360WB70 only Pilot orifice assemblyBurner blower configurations 7. PILOT PRESSURE ADJUSTMENT8. MAIN MANIFOLD PRESSURE ADJUSTMENT Gas pressure measurement/adjustment locations14” W.C./34.9mbar Yellow “NAT.” label placement on burner housing9. CONVERSION LABELING NATURALIncludes 4% reduction for each 1000 ft. above sea level, 4/02 Appendix - Equivalent Orifice Sizes at High AltitudesSECTION 3 - SERVICING COMPONENTS XI. ELECTRIC OVEN HEATING SYSTEM A. PS200-series ovens PS200 electric early with mercury contactors and fusesPS200 electric current with solid state relays and circuit breaker blocksIndividual element electrical data Removing elementsPart No. Description Electrical leads disconnectedRemoving the element bank mounting bolts B. PS310/360-series ovensSpacer brackets Element bank removed - spacer bracket visibleIndividual element electrical data 107WHeating 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 TO OBTAIN General conversion factorsPressure conversions MULTIPLYOhm’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