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Middleby Marshall PS200, PS570, PS360, PS555 Appendix - Service Bulletin MM-136 - Electrical Noise

Models: PS224 PS310 PS220 PS555 PS200 PS360 PS570

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Appendix - Service Bulletin MM-136 - Electrical Noise

SECTION 3 - SERVICING COMPONENTS

Appendix - Service Bulletin MM-136 - Electrical Noise

Filter Capacitor Assembly on Temperature Controllers, 9/93

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Middleby Marshall PS200, PS570, PS360, PS555 Appendix - Service Bulletin MM-136 - Electrical Noise, Servicing Components

Contents

Page PS200/220/224 Series PS310/360 Series PS555/570 Series 2002 Middleby Marshall, Inctechnical service manual This Technical Service Manual includes informationTABLE OF CONTENTS DISCONNECT THE OVEN FROM ITS ELECTRICAL POWER SUPPLY BEFORE SERVICINGTABLE OF CONTENTS continued Instructions for Service KitInstructions for Service Kits 33984 and 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 SECTION AIR FLOW AND HEAT TRANSFER Blowers, belts and pulleysI. TYPES OF HEAT TRANSFER II. BLOWERS AND BLOWER SPEEDAir finger operation PS300/350 air finger with shutter plateCurrent standard air finger all oven models B. PS360-series ovens3D air finger label if present Internal air finger chartB. Configuration and Alignment 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 9 - Conveyor Speed Bake Time Figure 11 - Time of DeliveryFigure 10 - Belt Time IV. OVEN CAPACITYSECTION SERVICING COMPONENTS Original-style speed controllerCurrent-style speed controller 4 or 8 DIP switches select oven modelPS350-style pickup assembly used on early PS360 Old-style pickup assembly2. Current-style pickup assembly see Figures C. Preparing to Service the Speed ControllerCurrent pickup assembly - side view Current pickup assembly end viewField Tester for Conveyor Drive Motor D. Controller/Motor Failure1. IF THE GEAR MOTOR RUNS AT FULL SPEED E. Basic Troubleshooting Flowcharts2. IF THE GEAR MOTOR WILL NOT RUN AT ALL SECTION 3 - SERVICING COMPONENTSMiddleby no longer stocks parts for the with a current modelConnections are reversed if conveyor direc- tion is reversed F. Initial Troubleshooting120VAC supply. Wire colors vary by oven model Connections for pickup test J. Unshielded Pickup Wires on Early PS360-series ovensG. Conveyor Control Pickup Test 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 Service Bulletin Middleby Cooking Systems GroupConveyor Speed Controller with Digital Display, P/N 37337, 8/00 SUBJECTMiddleby Corporation Service Hotline Conveyor Speed Controller Kit for PS200R68-series ovensfor PS200R68-series Ovens, 2/02 Instructions for Service KitAppendix - Service Bulletin MM-189 - New Conveyor Gear Motors Brushes, and Pickup Clamps, 8/01Service Bulletin Middleby Cooking Systems GroupII. TEMPERATURE CONTROLLER Appendix - DIP switch settings for Conveyor Speed Controllerwith Digital Display P/N 37337, 4/02 Figure 22 - Temperature controllers AB DEFG A. Part Number Reference - Temperature ControllersP/N 36056 G - Service Kit P/N P/N 46837 G - Service Kit P/NE. 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 4a Figure 5aFigure 5b Figure 4bJumper Setting ProgrammingPage 7 of Controller Service InstructionsTemperature Diagnostic Error Messages Page 8 ofDigital Temperature Controller P/N Operating Instructions Service KeyDisplay 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 Figure 23 - High limit control modules Shown in PS360-series oven C. Operation and TroubleshootingIII. HIGH LIMIT CONTROL MODULE A. Part Number Reference - High Limit Control Mod- ulesHigh Limit Conversion Kit for PS300, 310, 350, & 360 Ovens High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99Appendix - Instructions for Service Kit Instructions for Service KitAppendix - Instructions for Service Kit B. INSTALLATIONHigh Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 Page 2 ofAppendix - Instructions for Service Kit High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99NOT TO SCALE High limit thermocouple location lower ovenAppendix - Instructions for Service Kit C. WIRINGLighted Reset Switch Wiring and Installation Cooldown circuit wiringAppendix - Instructions for Service Kit D. TESTING THE INSTALLATIONHigh Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 Page 5 ofAppendix - Instructions for Service Kit ovens with a cooldown featurereplacement High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99Appendix - Instructions for Service Kit ovens without a cooldown featurereplacement High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99Appendix - Instructions for Service Kit Middleby Corporation Service HotlineHigh Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99 A MIDDLEBY COMPANYFigure 24 - Thermocouples TroubleshootingIV. THERMOCOUPLES A. Part Number Reference - ThermocouplesPage Oven Thermocouple Kit Instructions for Service Kits P/Ns 33984 andKIT CONTENTS - KIT P/N KIT CONTENTS - KIT P/NAppendix - Instructions for Service Kits 33984 and Oven Thermocouple Kit, 11/01Analog Temperature Controller Digital Temperature ControllerAppendix - Instructions for Service Kits 33984 and Thermocouple Installation - PS360 SeriesThermocouple Wiring - PS360 Series Oven Thermocouple Kit, 11/01Appendix - Instructions for Service Kits 33984 and Analog Temperature ControllerDigital Temperature Controller Oven Thermocouple Kit, 11/01Appendix - Instructions for Service Kits 33984 and Digital Temperature ControllerOven Thermocouple Kit, 11/01 PS536Appendix - Instructions for Service Kits 33984 and Oven Thermocouple Kit, 11/01NOTE FOR HIGH LIMIT THERMOCOUPLES 3. Disconnect the thermocouple leads. Refer to FigureAppendix - Instructions for Service Kits 33984 and Oven Thermocouple Kit, 11/01PS555 Electric and PS555E 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 Appendix - Instructions for Service Kits 33984 and Oven Thermocouple Kit, 11/01High limit thermocouple position for ovens withAppendix - Instructions for Service Kits 33984 and Oven Thermocouple Kit, 11/01High limit thermocouple High limit thermocoupleAppendix - Instructions for Service Kits 33984 and Oven Thermocouple Kit, 11/01Left RightAppendix - Instructions for Service Kits 33984 and Thermocouple Wiring - PS555G and PS570GMiddleby Corporation Service Hotline Oven Thermocouple Kit, 11/01Early-style PS200 indirect drive assembly Current PS200 indirect drive assemblyBlower motor fuses V. BLOWERS A. PS200-series ovensBearing lubrication Blower belt tensionRepositioning the blower motor Loosen bolts to reposition motor and adjust belt tensionFan shaft alignment tool Part Number DescriptionNot available Not availableCord must touch sheaves at four points indicated by arrows Figure 33 - Four-point alignment test for correct pulley alignmentCord tied to shaft date early-style fan shaft assembly to the current version shown here Part NumberDescription Part NumberB. PS360-series ovens Blower motor fuses - single-phase motorsBlower motor fuses - three-phase motors Figure 39 - Blower wheel placement Shown from rear of oven Figure 37 - Clockwise blower wheelFigure 38 - Counterclockwise blower wheel Inlet ringFigure 42 - PS570/570S blower configuration Figure 43 - PS555/570G blower configurationFigure 44 - Fuse/circuit breaker locations A. PS555/570-series ovensPart Number Description Part NumberDescription OvenPS500-series blower wheel orientation Bearing lubricationBlower belt tension and repositioning the blower motor Figure 48 - Four-point alignment test for correct pulley alignmentFigure 49 - PS360-series blower motor centrifugal safety switch VI. BLOWER MOTOR CENTRIFUGAL SAFETY SWITCH PS360-SERIESA. Part Number Reference - Blower Centrifugal Switch B. TroubleshootingFigure 50 - Air pressure safety switch models Dungs square-case “replacement” air switch with screw adjustmentPS360WB70/EWB with Midco burner PS360WB70/EWB with Wayne burnerB. Troubleshooting Connects to negative pressure side of air switchAppendix - Instructions for Service Kits 35624 and Air Pressure Switch Replacement Kits, 1/97SECTION 3 - SERVICING COMPONENTS 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 PS570/570S flame gate adjustment Adjustment rodIX. PS570/570S FLAME GATE A. Part Number Reference - Flame GatePS200-series gas train PS310, PS314, PS360 or PS360WB gas trainX. GAS TRAIN AND BURNER SYSTEM A. Part Number ReferencePS360EWB or PS360WB70 gas train with Midco burner PS360EWB or PS360WB70 gas train with Wayne burnerSWITCH SWITCHPS570S gas train PS570G or PS555 gas trainNOT SHOWN components are installed on back wall of machinery SWITCHFigure 60 - Wayne burner - exploded view B. Part Number Reference - Gas Orifices and Gas Conversion Kitssame as natural gasFigure 61 - Midco burner Figure 62 - Wayne burnerC. Component Identification 1. Burner typeFigure 63 - Pilot/ignitor assembly End of burner without flame target showing pilot shieldFlame targets D. Pilot/Ignitor AssemblyFlame structure Figure 67 - Flame rectification Figure 68 - Pilot and probeFlame Rectification VoltageAir shutter adjustment TemperaturePilot Application Burner Blower MotorLow Flame Bypass Orifice G. Burner TransformerH. Burner Motor Relay I. High Flame Solenoid Valve if so equippedFigure 71 - Modulating Gas System Digital TemperatureK. Modulating Gas Valve if so equipped L. Amplifier Board ovens with a modulating gas valve onlyFigure 72 - Combination Gas Control Valve Burrs in pilot adjustment portalM. Combination Gas Control Valve Pilot pressureN. Ignition Module P. Burner and Gas Train Troubleshooting O. Gas Conversion Kits1. Burner Blower Motor 3. RelayVoltage Checks for Ignition Module and Combination Gas Valve 8. System Troubleshooting5. Burner Operation 6. Check Grounding9. Component Checks Reset System After Lockout 10. Check Spark Ignition Circuit11. Check Spark Ignitor 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 TORY BEFORE INSTALLING THIS KIT ENGLISH- page ESPAÑOL - páginaPS360EWB all PS555 all PS570S units produced 4/00 or later KIT COMPONENTSENGLISH Appendix - Instructions for All Gas Conversion Kitsfor Ovens with Wayne Burner, Natural Gas to Propane, 8/00 Typical PS200-series gas train configurationI. PREPARATION AND DISASSEMBLY II. COMBINATION GAS CONTROL VALVE SAFETY REGULATORCONVERSIONENGLISH Appendix - Instructions for All Gas Conversion KitsVI. REASSEMBLY ENGLISHAppendix - Instructions for All Gas Conversion Kits for Ovens with Wayne Burner, Natural Gas to Propane, 8/00IX. PILOT PRESSURE ADJUSTMENT STAND WELL CLEAR WHEN SWITCHING ONRemove the pilot adjustment cap screw from the 4. If no leaks are detected by the test, depress the safetyX. MANIFOLD PRESSURE ADJUSTMENT Appendix - Instructions for All Gas Conversion Kitsfor Ovens with Wayne Burner, Natural Gas to Propane, 8/00 XI. MARKING AND LABELINGENGLISH- page ESPAÑOL - página KIT COMPONENTSfor Ovens with Wayne Burner, Propane to Natural Gas, 8/00 Propane to Natural Gas Operationfor Ovens with Wayne Burner, Propane to Natural Gas, 8/00 Typical PS200-series gas train configurationTypical PS300-series gas train configuration Typical PS555 or PS570S gas train configurationI. PREPARATION AND DISASSEMBLY II. COMBINATION GAS CONTROL VALVE SAFETY REGULATORCONVERSIONENGLISH Appendix - Instructions for All Gas Conversion KitsVI. REASSEMBLY ENGLISHAppendix - Instructions for All Gas Conversion Kits for Ovens with Wayne Burner, Propane to Natural Gas, 8/00IX. PILOT PRESSURE ADJUSTMENT ENGLISHAppendix - Instructions for All Gas Conversion Kits for Ovens with Wayne Burner, Propane to Natural Gas, 8/00X. MANIFOLD PRESSURE ADJUSTMENT Appendix - Instructions for All Gas Conversion Kitsfor Ovens with Wayne Burner, Propane to Natural Gas, 8/00 SECTION 3 - SERVICING COMPONENTSMiddleby Marshall PS360EWB and PS360WB70Natural Gas to Propane Installation Instructions 2. PILOT ORIFICE REPLACEMENT3. MAIN ORIFICE REPLACEMENT 4. LOW FLAME ORIFICE REPLACEMENT PS360WB70 onlyPilot orifice assembly Low flame orifice replacement7. PILOT PRESSURE ADJUSTMENT 8. MAIN MANIFOLD PRESSURE ADJUSTMENTGas pressure measurement/adjustment locations Burner blower configurationsRed “LPG.” label placement on burner housing Conversion information label placement PS360EWB placementPS360WB70 placement 9. CONVERSION LABELINGPropane to Natural Gas Installation Instructions 2. PILOT ORIFICE REPLACEMENTOrifice, Pilot Assembly - Natural Gas, 0.032” 0.81mm Middleby Marshall3. MAIN ORIFICE REPLACEMENT 4. LOW FLAME ORIFICE REPLACEMENT PS360WB70 onlyPilot orifice assembly Low flame orifice replacement7. PILOT PRESSURE ADJUSTMENT 8. MAIN MANIFOLD PRESSURE ADJUSTMENTGas pressure measurement/adjustment locations Burner blower configurationsYellow “NAT.” label placement on burner housing 9. CONVERSION LABELINGNATURAL 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 PS200 electric early with mercury contactors and fuses PS200 electric current with solid staterelays and circuit breaker blocks XI. ELECTRIC OVEN HEATING SYSTEM A. PS200-series ovensRemoving elements Individual element electrical dataElectrical leads disconnected Removing the element bank mounting boltsB. PS310/360-series ovens Part No. DescriptionElement bank removed - spacer bracket visible Individual element electrical data107W Spacer bracketsRefer to Temperature Controller on Page 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 General conversion factors Pressure conversionsMULTIPLY 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