Middleby Marshall PS528-SERIES PS528G, Owner'S Operating And Installation Manual

Page 1: ...by Marshall Inc A MIDDLEBY COMPANY PS528 Series Gas Ovens English owner s operating installation manual PS528 Series OVENS Model PS528G PS528 Triple PS528 Double Part No 63935 Rev B Price 30 00 P 08 09 PS528 Single ...

Page 2: ...al should be given to the user The operator of the oven should be familiar with the functions and operation of the oven This manual must be kept in a prominent easily reachable location near the oven Ovens are shipped from the factory configured for use with natural gas If permitted by local national and international codes at the time of installation the oven may be converted to propane gas opera...

Page 3: ...IFICALLY THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE The foregoing shall be Seller s sole and exclusive obligation and Buyer s sole and exclusive remedy for any action whether in breach of contract or negligence In no event shall seller be liable for a sum in excess of the purchase price of the item Model No Modéle No Serial No Serié No Installation Da...

Page 4: ...0 B Blower Switch 20 C Heat Switch 20 D Temperature Controller 20 E Conveyor 21 MEASURING CONVEYOR SPEED 21 TABLE OF CONTENTS Continued Page III STEP BY STEP OPERATION 22 A Startup Procedures 22 Daily Startup 22 Power Failure 22 B Shutdown Procedure 22 IV NORMAL OPERATION STEP BY STEP 24 A Daily Startup Procedure 24 B Daily Shutdown Procedure 24 V QUICK REFERENCE TROUBLESHOOTING 26 SECTION 4 MAINT...

Page 5: ...e 1 2 consists of two stacked single ovens A triple oven Figure 1 3 consists of three stacked single ovens The lower oven is mounted on a base pad with stacking pins On a double or triple oven the ovens operate indepen dently All ovens use identical controls and components One oven can be cleaned or serviced while the others are operating SECTION 1 DESCRIPTION Figure 1 1 Single PS528 Oven Figure 1...

Page 6: ...y Inlet Pressure IT PT ES SE Main UK CH IT AT SE CH AT DK BE IE IT PT Orifice Rated Gas Orifice DK FI DE BE FR FI DE NL ES UK Manifold Heat Type dia I2H I2E I2E I3B P I3 Pressure Input G20 2 3749 20 20 20 11 21 22 36 mm mbar mbar mbar mbar kW hr G25 2 3749 16 19 22 36 mm mbar kW hr G30 1 3970 29 or 50 28 30 37 26 2 22 59 mm mbar or 50 mbar mbar kW hr Gas orifice and pressure specifications per ove...

Page 7: ...SECTION 1 DESCRIPTION 3 II COMPONENT FUNCTION Figure 1 4 Figure 1 4 PS528 Series Oven Components Locations ...

Page 8: ...led by the temperature controller D Cooling Fan See Figure 1 5 and Figure 1 6 The cooling fan is located in the back of the oven The cooling fan draws air through its grille blowing it through the blower motor compartment and the control compartments into the oven top and exhausted out the front louvers E Air Fingers and Blank Plates See Figure 1 7 E1 Air Fingers An Air Finger Assembly is made up ...

Page 9: ...SECTION 1 DESCRIPTION 5 Figure 1 6 Cooling Fan ...

Page 10: ...6 SECTION 1 DESCRIPTION Figure 1 7 Blank Plates two sizes and an Air Finger F2 Blank Plates 1 Blank Plates The Blank Plates are available to install on the plenum where an air finger is not required ...

Page 11: ...ust conform with local codes In the absence of local codes gas oven installations must conform with the Natural Gas Installation Code CAN CGA B149 1 or the Propane Gas Installation Code CAN CGA B149 2 as applicable Installed ovens must be electrically grounded in accordance with local codes or in the absence of local codes with the Canadian Electrical Code CSA C22 2 NOTE In the USA the oven instal...

Page 12: ...jacent combustible con struction Clearance must also be provided for servicing and for operation CAUTION Itisrecommendedthattheovenbeplacedunder a ventilation hood for adequate air supply and ventilation CAUTION Do not obstruct the flow of ventilation air to and from your oven Do not obstruct the fan holes in the rear of the unit I UNLOADING Your Middleby Marshall PS528 Series Oven is shipped part...

Page 13: ... 4 1 2 12 2 59227 HEAT GUARD 13 4 62207 INSULATION PARTS LIST FOR SERIES PS528 Gas OVEN INSTALLATION KIT Triple Stack Oven P N 63948 7 8 ITEM NO QTY PART NO DESCRIPTION 1 2 62208 INSULATION BOTTOM TRAY 2 1 62206 BOTTOM TRAY WELDMENT 3 1 61650 TOP COVER 4 4 51387 SCREW MSSLT THREAD 8 32 1 2 18 8 5 4 3101908 LEG 4 AD FT 7 1 22450 0228 GAS HOSE RESTRAINT CABLE 8 2 22361 0001 GAS HOSE 9 1 49975 CORD P...

Page 14: ...10 SECTION 2 INSTALLATION Figure 2 5 MODEL PS528 SINGLE OVEN DIMENSIONS The Opening Height is Adjustable from 2 1 4 inch minimum to 3 3 4 inch maximum in 1 2 inch increments 1 1 ...

Page 15: ...LATION 11 Figure 2 6 MODEL PS528 DOUBLE OVEN DIMENSIONS 1 The Opening Height is Adjustable from 2 1 4 inch mini mum to 3 3 4 inch maximum in 1 2 inch increments P N 59927 is shown in its correct installed position 1 2 ...

Page 16: ...STALLATION Figure 2 7 MODEL 528 TRIPLE OVEN DIMENSIONS 1 The Opening Height is Adjustable from 2 1 4 inch mini mum to 3 3 4 inch maximum in 1 2 inch increments P N 59927 is shown in its correct installed position 1 2 ...

Page 17: ...f the oven s to allow convenient access to safety switches UTILITY ROUGH IN DIMENSIONS AND POSITIONING FOR PS528 SERIES OVENS CAUTION UNIT MUST HAVE AIR VENT PLATES INSTALLED OR WARRANTY WILL BE VOID II VENTILATION GUIDELINES A mechanically driven ventilation system is required for the PS528 Series Middleby Marshall conveyorized gas ovens Local codes and conditions vary greatly from one area to an...

Page 18: ...furnished MUST be installed in the electric supply line for each oven it is recommended that this switch circuitbreakerhavelockout tagoutcapability The electricsupplyconnectionmustmeetallnationalandlocal electricalcoderequirements Copperistherecommended material for the electrical supply conductors IV ELECTRIC SUPPLY FOR GAS HEATED OVENS Power requirements for gas heated ovens are 208 240VAC 1 pha...

Page 19: ...ssembly fourscrews Slideoutthemanifold assembly leaving the ignition and sense wires connected Replace the main orifices Replace the main orifices on the manifold assemblies with the LP units and replace the manifold assembly Reconnect the union D Adjusting the Maximum Pressure Setting 1 Disconnect pressure feedback connection if applicable 2 Connect a suitable pressure gauge to pipe line or to ou...

Page 20: ...hAGACodes AG311 and AG601 and with any requirements of the appropriate statutory authority In CE countries the gas supply connection should be according to EN 203 gas appliance directive and to applicable ISO 228 1 or ISO 7 1 recommendations All aspects of the gas supply connection must comply with current IEC CEE requirements and with all applicable local national and international codes Forallov...

Page 21: ...llow the oven to operate c Openthemaingassupplyvalve Switchthecircuitbreaker fused disconnect to the ON I position d Start the oven according the directions in the Operation section of this Manual Adjust the temperature controller to the maximum setting 316 C e Measure the supply inlet pressure f Switch the oven off Close the main gas supply valve and switch the circuit breaker fused disconnect to...

Page 22: ...18 SECTION 2 INSTALLATION NOTES ...

Page 23: ...g parts and electric shock exists in this oven Never disassemble or clean the oven with the BLOWER switch or any other oven control turned ON or I Turn OFF or O and lockout or tagout all electric power to the oven before attempting to clean or service this oven Figure 3 1 PS528 Series Oven Control Functions ...

Page 24: ... thermostatic override is built into the oven If the temperature inside the oven is over 180 F 82 C themainblowerwillcontinuetorunaftertheblowerswitch is turned to the OFF or O position C Heat Switch The HeatSwitch allowstheburnertoactivate Activation is determined by the settings on the Digital Temperature Controller D Temperature Controller The temperature controller is a solid state PID type to...

Page 25: ... leading edge of the item to go from the entrance end of the baking chamber to the exit end This should be the conveyor speed shown on the con veyor speed digital control NOTE In Figures 3 4 and 3 5 the oven shown is with the conveyor running right to left WARNING Possibility of injury from rotating parts and electrical shock exist in this oven Never disassemble or clean the oven with the blower s...

Page 26: ...w 140 F 60 C 3 TurntheCONVEYORswitch Figure3 6 tothe ON or I position This starts the conveyor belt moving through the oven Set the conveyor speed for the desired baking time Refer to the following Procedures E F and G 4 Set the temperature controller to the desired baking temperature NOTE For complete temperature controller operation instructions refer to Step C 5 Turn the HEAT switch Figure 3 6 ...

Page 27: ...SECTION 3 OPERATION 23 Figure 3 6 Control Panel ...

Page 28: ... the setpoint temperature Higher setpoint temperatures will require a longer wait The oven can reach a temperature of 500 F 232 C in approximately 15 minutes 3 After the oven has cooled and the blowers have turned to the OFF or O position switch the circuit breaker fuse disconnect to the OFF or O position 2 Make certain that there are no products left on the conveyor inside the oven Turn the CONVE...

Page 29: ...ey Press this key togeth er with the Set Point Key to allow the Set Point to be changed Changes can only be made for 60 seconds Up Arrow and Down Arrow Keys Press these keys to adjust the Set Point up or down If the Set Point will not change refer to Set Point Key and Unlock Key in this section Set Point Key Press this key togeth er with the Unlock Key to allow the Set Point to be changed Changes ...

Page 30: ...ck that the BLOWER Switch is in the ON I position Turn the HEAT BLOWER and CONVEYOR switches to the OFF O position Wait for AT LEAST FIVE MINUTES before restarting the oven Repeat the Daily Startup procedure Check that the Set Point is correctly set Check that both the BLOWER and HEAT Switches are in the ON I position If the oven still will not heat turn the HEAT BLOWER and CONVEYOR switches to th...

Page 31: ... Move oven to desired location for servicing 4 When servicing is complete move oven to original location 5 Adjust legs to level oven 6 Connect electrical connectors to oven 7 Turn on main circuit breakers 8 Follow normal startup instructions WARNING Before ANY cleaning or servicing of the oven perform the following procedure 1 Switch off the oven and allow it to cool Do NOT service the oven while ...

Page 32: ... OVEN Replace cooling fan blade beforeoperatingoven Seriousdamage could be done to the burner blower motor and or solid state electrical components if oven is operated while cooling fan is not running or vent grille is plugged 3 Using a stiff nylon brush clean control compartment vent grille C Conveyor Belt Figure 4 2 Everyday just after starting the oven stand at the un loading end of the conveyo...

Page 33: ...irst remove all heavy debris with a vacuum cleaner Use a damp cloth for light clean ing For heavier cleaning of baked on grease and carbon deposits use a non caustic cleaner that will not react with the aluminized finger manifold surfaces You can order non caustic cleaner from your local authorized Middleby Marshall Parts Distributor in the quantities listed Part Quantity 27170 0244 Case of Quarts...

Page 34: ...CTION 4 MAINTENANCE side 6 Remove conveyor as shown Figure 4 6 Figure 4 7 CAUTION Be careful not to bump the drive sprocket while handling the conveyor to avoid damaging the drive shaft Figure 4 4 Figure 4 5 ...

Page 35: ...rs 2 Slide blank plates straight out Figure 4 8 3 Remove air fingers NOTE Someovenusersrequireacustomfingerarrange ment where the quantity of air fingers may vary You can remove top and bottom fingers and blank plates from each or either end It is highly recommended that each finger be marked before removing so it is placed in exactly the same position when reassembled refer to step 1 Remove the a...

Page 36: ...Finger C Reassembly of Air Fingers 1 Air fingers are made up of one inner plate one outer plate and the finger housing manifold Be sure to match up the markings T1 T2 T3 etc on all the parts of the air fingers as you are reassembling Figure 4 14 2 Reassemble the inner plate Keep your fingers clear so you won t pinch them The inner plate of a finger will only go in one way because of its design 3 R...

Page 37: ...ay they came out IMPORTANT When inserting fingers the tab on the outer plate must be in the groove as shown in Figure 4 18 There is a blocking tab on the outside of the groove which will prevent inserting the finger in the groove if the outer plate is moved away from the flange of the finger manifold Figure 4 16 Figure 4 17 Extended Lip Flange of Finger Manifold Tab on Outer Plate Tab on Outer Pla...

Page 38: ...n edges Figure 4 18 Top Finger Incorrect Too Much Space Blank Plate Tab on Outer Plate of Finger Located in Groove Top Finger Incorrect Too Much Space Blank Plate Tab on Outer Plate of Finger Located in Groove Top Finger Correct Edges Overlap Com pletely Blank Plate Tab on Outer Plate of Finger Located in Groove ...

Page 39: ...35 D Reinstall End Plugs 1 Reinstall lower end plug Be sure to tighten the wing screw on the end plug 2 Reinstall conveyor 3 Reinstall upper end plug Be sure to tighten two wing screws on the end plug Figure 4 19 Figure 4 20 ...

Page 40: ... tension an entire link must be removed Use the following procedure H Conveyor Belt Link Removal to remove a link If conveyor belt is under proper tension proceed directly to J Attaching Drive Chain Figure 4 23 G Conveyor Belt Link Removal E Conveyor Reassembly Into Oven 1 Lift conveyor and position it in oven as shown NOTE Conveyormaybeinsertedintoeitherendofoven If it is to be installed from the...

Page 41: ...emoved 5 Pull up on the belt link section and remove Do not discard the link removed as it may be used for making spare master links NOTE If a section of the conveyor belt is being replaced it should be done now Remove the links that need re placing and use the section of conveyor belt furnished in your installation kit to replace them Figure 4 27 NOTE Before connecting the inside master links not...

Page 42: ...derside of the con veyor must be against the lower end plug This is true on both sides of oven Figure 4 33 6 Reconnect the inside master links Figure 4 29 Figure 4 29 NOTE The outside master links have right and left sides to them The right edge master link has an open hook facing you as shown in Figure 4 30 This will match up with the outer edges of the conveyor belt Remember this hook travels ba...

Page 43: ... contactor terminal screws as shown in Figure 4 35 Figure 4 35 B Ventilation Check that the air circulation throughout the oven is not blocked and is working properly IV MAINTENANCE EVERY 6 MONTHS A Check brushes on D C conveyor motor when worn to less than 1 10 2 4mm replace the brushes B Check your oven venting system C Inspect and clean the burner nozzle and the spark electrode assembly IMPORTA...

Page 44: ...1 2 58390 Motor Conveyor Drive w Magnet 1 3 60671 Board Amplifier Signal 0 15VDC 1 4 32108 XFMR 240V PRI 24V 65VA SEC 1 5 33812 5 Thermocouple Type J Shielded 2 50 x 120 3 6 33813 Filter RFI 1 7 38185 Assembly Pickup Sensor 1 8 41872 Transformer 240V P 24V S 25VA 1 9 44696 Switch Rotary and Mounting Adapter 2 10 44697 Block Contact 3 11 45644 Breaker Circuit 240V 1A 1 12 48455 Ignitor Single Rod 1...

Page 45: ...ning Refer to Section 4 procedure or call your Middleby Marshall Service Agency PROBLEM OVEN BLOWER AND CONVEYOR OPERATE YET THE OVEN IS NOT HEATING Start the oven again If the oven still does not heat call your Middleby Marshall Service Agency Reset the temperature controller to a new setting above 200 F after turning the BLOWER switch to off for 30 seconds PROBLEM OVEN DOES NOT TURN ON WHEN ITS ...

Page 46: ...SECTION 5 TROUBLESHOOTING 42 NOTES ...

Page 47: ...43 SECTION 6 ELECTRICAL SCHEMATICS SECTION 6 ELECTRICAL SCHEMATICS Wiring Diagram G208 240 50 60 GO PS528G P N 62317 REV B ...

Page 48: ...y or death Read the installation operating and maintenance instructions thoroughly before installing or servicing this equipment NOTICE During the warranty period ALL parts replacement and servicing should be performed by your Middleby Marshall Authorized Service Agent Service that is performed by par ties other than your Middleby Marshall Authorized Service Agent may void your war ranty NOTICE Us...