technical service

manual
This Technical Service Manual includes information
for the following oven models:
• PS200/220/224 Series
• PS310/360 Series
• PS555/570 Series

P/N 47829 • Rev. C • V1 • 4/02

Middleby is proud to support the

Commercial Food Equipment Service Association (CFESA).
We recognize and applaud CFESA’s ongoing efforts
to improve the quality of technical service in the industry.

© 2002 Middleby Marshall, Inc.

is a registered trademark of Middleby Marshall, Inc. All rights reserved.

Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • (847) 741-3300 • FAX (847) 741-4406 • 24-Hour Service Hotline (800) 238-8444
1
 WARNING
Improper installation, adjustment, alteration, service or maintenance can cause
property damage, injury or death. Read the installation, operating and maintenance
instructions thoroughly before installing or servicing this equipment.

WARNING
DISCONNECT THE OVEN FROM ITS ELECTRICAL
POWER SUPPLY BEFORE SERVICING.

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 parties other than
your Middleby Marshall Authorized Service Agent may void your warranty.
NOTICE
Using any parts other than genuine Middleby Marshall factory manufactured parts relieves the
manufacturer of all warranty and liability.
NOTICE
Middleby Marshall reserves the right to change specifications at any time.

TABLE OF CONTENTS
Section 1 - Sequence of Operation .................................................... 4 F. Initial Troubleshooting ......................................................... 18
I. Gas Oven Sequence of Operation ............................................. 4 G. Conveyor Control Pickup Test ............................................ 19
II. Electric Oven Sequence of Operation ....................................... 6 H. Conveyor Motor Test .......................................................... 19
I. Replacing the Magnetic Pickup .......................................... 19
Section 2 - Air Flow and Heat Transfer ............................................. 7 J. Unshielded Pickup Wires on Early PS360-series Ovens . 19
I. Types of Heat Transfer ............................................................... 7 K. Appendices ......................................................................... 20
II. Blowers and Blower Speed ....................................................... 7 • Conveyor sensor wiring changes for PS360-series
A. PS200-series ovens ............................................................ 7 and PS570S, 10/95 .................................................... 20
B. PS360-series ovens ............................................................ 8 • Service Bulletin MM-133B - Installation Instructions
C. PS555/570-series ovens .................................................... 8 for Conveyor Speed Controller Kit with Thumbwheel,
P/N 42810-0133, 4/95 ................................................ 21
III. Air Fingers ................................................................................... 8
• Instructions for Service Kit 42810-0133- Conveyor
A. Description and Function .................................................... 8
Speed Controller Kit with Thumbwheel, 4/95 .......... 23
B. Configuration and Alignment ............................................... 9
• Service Bulletin MM-177 - Introduction and Compat-
C. Performing a Test Bake ....................................................... 9 ibility of Conveyor Speed Controller with Digital
D. PS300/350 Air Finger Shutter Adjustment ......................... 10 Display, P/N 37337, 8/00 ........................................... 27
IV. Oven Capacity ............................................................................ 12 • Instructions for Service Kit 44756 - Conveyor Speed
A. Conveyor Speed and Bake Time ....................................... 12 Controller Kit for PS200R68-series Ovens, 2/02 ... 28
B. Belt Time .............................................................................. 12 • Service Bulletin MM-189 - New Conveyor Gear
C. Time of Delivery (TOD) ....................................................... 12 Motors, Brushes, and Pickup Clamps, 8/01 ............ 29
• DIP switch settings for Conveyor Speed Controller
with Digital Display (P/N 37337), 4/02 ..................... 30
Section 3 - Troubleshooting and Servicing Components
II. Temperature Controller ............................................................... 30
I. Conveyor Speed Controller and Drive Motor ............................. 13
A. Part Number Reference - Temperature Controllers .......... 31
A. Part Number Reference - Speed Controllers .................... 13
B. Description .......................................................................... 32
B. Part Number Reference - Pickup Assemblies ................... 14
C. High Limit/Cooldown Functions .......................................... 32
C. Preparing to Service the Speed Controller ........................ 14
D. Troubleshooting .................................................................. 32
D. Controller/Motor Failure ...................................................... 15
E. Appendices ......................................................................... 32
E. Basic Troubleshooting Flowcharts ................................... 16
• Temperature Controller Terminal
• If the Conveyor Runs at Full Speed ......................... 16
Cross-Reference, 4/02 .............................................. 32
• If the Conveyor Will Not Run at All .......................... 17
• Instructions for Service Kit 47321 - Digital
Temperature Controller Kit, 2/02 .............................. 33
• Service Bulletin MM-136 - Electrical Noise Filter
Capacitor Assembly on Temperature Controllers,
9/93 ............................................................................. 43
2
 TABLE OF CONTENTS (continued)
III. High Limit Control Module ........................................................... 45 R. Troubleshooting Flowcharts ........................................... 103
A. Part Number Reference - High Limit Control Modules ...... 45 • Intermittent Pilot System Troubleshooting Table 103
B. Location .............................................................................. 45 • No Spark, System Does Not Work ........................ 104
C. Troubleshooting .................................................................. 45 • Spark is Present, Pilot Will Not Light ................... 105
D. Appendices ......................................................................... 46 • Pilot Lights, Main Valve Will Not Come On ......... 106
• Instructions for Service Kit 39733 - S. Appendices ...................................................................... 107
High Limit Conversion Kit for PS300, 310, • Instructions for Service Kit 42810-0117 -
350 & 360 Ovens, 5/99 ..............................................46 Pilot/Ignitor Kit, 7/91 ............................................... 107
IV. Thermocouples ........................................................................... 54 • Instructions for Service Kit 30185 - Pilot Tee, 3/94 . 108
A. Part Number Reference - Thermocouples ........................ 54 • Instructions for Service Kit 42810-0121 -
B. Thermocouple Functions ....................................................54 Combination Gas Valve, 1/92 ................................ 112
C. Troubleshooting .................................................................. 54 • Instructions for Service Kit 42810-0114 -
D. Appendices ......................................................................... 56 Ignition Module, 11/90 ............................................. 116
• Instructions for Service Kits 33984 and 33985 - • Position of Combination Gas Valve Components
Oven Thermocouple Kit, 11/01 ................................. 56 during Burner Operation, 4/02 ................................ 118
V. Blowers .................................................................................... 68 • Instructions for All Gas Conversion Kits
A. PS200-series ovens ........................................................... 68 for Ovens with Wayne Burner, Natural Gas to
B. PS360-series ovens ........................................................... 74 Propane, 8/00 ........................................................... 119
C. PS555/570-series ovens ................................................... 76 • Instructions for All Gas Conversion Kits
for Ovens with Wayne Burner, Propane to
VI. Blower Motor Centrifugal Safety Switch (PS360-series) ....... 80
Natural Gas, 8/00 ................................................... 125
A. Part Number Reference - Blower Centrifugal Switch ...... 80
• Instructions for Service Kit 36856 - Gas
B. Troubleshooting .................................................................. 80 Conversion Kit for PS360EWB/WB70 with
VII. Burner Blower Motor Centrifugal Safety Switch (PS200- Midco Burner, Natural Gas to Propane, 1/98 ....... 131
series gas, PS310, PS314, PS360, PS360WB, PS570S) ......... 80 • Instructions for Service Kit 36863 - Gas
VIII. Air Pressure Safety Switch (PS200-series, PS555/570- Conversion Kit for PS360EWB/WB70 with
series, PS360EWB, PS360WB70) ............................................. 81 Midco Burner, Propane to Natural Gas, 1/98 ....... 135
A. Part Number Reference - Air Switches ............................81 • Equivalent Orifice Sizes at High Altitudes, 4/02 . 139
B. Troubleshooting .................................................................. 82 XI. Electric Oven Heating System ................................................ 140
C. Appendices ......................................................................... 83 A. PS200-series ovens ........................................................ 140
• Instructions for Service Kits 35624 and 35625 - B. PS310/360-series ovens ................................................ 142
Air Pressure Switch Replacement Kits, 1/97 ..........83 C. PS555 ovens .................................................................... 144
• Instructions to Replace an “Alternate” Air Switch D. Electric Oven Mercury Contactor Replacement ............ 146
P/N 36194 with Service Kit P/N 35624, 3/97 ........... 85
IX. PS570/570S Flame Gate ............................................................. 87
Section 4 - Electrical Wiring Diagrams ............................................ 149
A. Part Number Reference - Flame Gate ............................... 87
I. Component Wiring .................................................................... 149
B. Flame Gate Orientation ....................................................... 87
A. Temperature Controllers .................................................. 149
X. Gas Train and Burner System ................................................... 88
B. Ignition Modules ............................................................... 150
A. Part Number Reference - Gas Train Components ............ 88
II. PS200-series Ovens ............................................................... 151
B. Part Number Reference - Gas Orifices and Gas
III. PS310/360-series Ovens ........................................................ 160
Conversion Kits .................................................................. 91
IV. PS555/570-series Ovens ........................................................ 166
C. Component Identification ....................................................92
D. Pilot/Ignitor Assembly ..........................................................93
Section 5 - Reference ..................................................................... 172
E. Burner Blower Motor ..........................................................95
• 25-point preventative maintenance checklist ....................... 172
F. Air Shutter ........................................................................... 95
• Fractional inches to decimal and millimeter equivalents ... 173
G. Burner Transformer ........................................................... 96
• Decimal equivalents of drill sizes ......................................... 173
H. Burner Motor Relay ............................................................ 96
• General conversion factors ................................................... 174
I. High Flame Solenoid Valve ................................................. 96
• Pressure conversions ............................................................ 174
J. Bypass (Low Flame) Orifice ............................................. 96
• Pressure conversion chart ..................................................... 175
K. Modulating Gas Valve ......................................................... 97
• Ohm’s Law equation wheel .................................................... 175
L. Amplifier Board ................................................................... 97
• Common electrical wiring diagram symbols ........................ 176
M. Combination Gas Control Valve ......................................... 98
N. Ignition Module .................................................................... 99
O. Gas Conversion Kits ....................................................... 100
P. Burner and Gas Train Troubleshooting .......................... 100
Q. Checking the Gas Pressures .......................................... 102

3
SECTION 1 - SEQUENCE OF OPERATION

SECTION 1
SEQUENCE OF OPERATION
I. GAS OVEN SEQUENCE OF OPERATION D. Blower Switch
A. Electrical Supply Closing the blower switch energizes:
Gas heated ovens operate on 208/240V, single phase. 1. The cooling (axial) fan(s).
Standard incoming power configurations are: 2. The blower motor contactor (s).
1. 4-wire system (PS200 series, PS310/360 series, Closing this contactor starts the blower motor(s). When
PS570, PS570S) - 2 single phase 208/240V sup- both blower motors are up to speed, centrifugal switches
ply (hot) lines, 1 neutral and 1 ground. located inside the blower motors (or air switches de-
2. 3-wire system (PS360WB70, PS360EWB, PS555, tecting blower operation, as appropriate for the oven
PS570G, PS536) - 2 single phase 208/240V sup- model) will close, setting up the heat circuit.
ply (hot) lines and 1 ground. 3. The Temperature Controller.
For all wiring configurations, the voltage when measured E. Heat Switch
from either hot line to neutral should never exceed 130V.
Closing the heat switch completes a circuit:
B. Door Switch
1. Through the heat switch.
Closing the control cabinet door (or machinery com-
partment door, as appropriate for the oven model) will 2. Through the blower motor centrifugal switches (or
close the door switch and allow the oven to operate. air switches, as appropriate for the oven model).

Note that the electrical systems will still be “live” 3. Through the high limit switch.
if the switch is open, although the oven cannot 4. One circuit then goes to the:
operate. a. Burner (L1).
The door switch has a bypass position to enable ser- b. Transformer (110V to 24V).
vice operation with the door opened. When the door is
c. Motor relay coil. On a cold start the heater on
open, grasp the switch actuator and pull it out as far as
this relay takes about 30 seconds to warm up
possible. This will close the door switch and permit
before the relay will energize. This gives an
troubleshooting. Closing the control cabinet door will
additional prepurge. The relay is not used on
reset the switch.
ovens with 208/240V burner blower motors.
1. Closing the door switch permits a circuit to go
d. Burner blower motor. As the motor reaches full
through a fuse (or circuit breaker, as appropriate
operating speed, the centrifugal switch (or air
for the oven model) to one side of the conveyor
flow switch, as appropriate for the oven model)
switch, blower motor switch, cooldown relay and
closes and applies voltage to the burner con-
heat switch.
trol. This energizes the ignitor control spark
2. Closing the door switch permits a circuit to go transformer and the pilot valve. The spark then
through the motor fuse (two 9A or 15A fuses per lights the pilot. The flame sensor proves the
motor). presence of the pilot flame, and the ignitor con-
C. Conveyor Switch trol then shuts off the spark. At the same time,
Closing the conveyor switch permits a circuit to go to the main burner valve is opened. The main
the Conveyor Speed Control Module, which: burner is then ignited.

1. Sends power to the gear motor (conveyor drive mo- If the pilot does not light within approximately
tor). The 120VAC signal to the Conveyor Speed 90 seconds, the oven will shut down.
Control Module is rectified to a 90VDC signal which The pilot and main gas valve will stay on (open)
is then sent to the gear motor. as long as the heat switch is ON and the flame
2. Allows regulation of conveyor speed. Adjusting the is proven. If the flame goes out for any reason,
thumbwheel (or digital pushbutton display unit, as the pilot will try to light for 90 seconds, and
appropriate) to the desired conveyor belt speed in- then go into automatic lockout. To relight the
structs the Conveyor Speed Control Module to regu- pilot after it has gone into automatic lockout,
late the output to the gear motor. This increases the burner must be turned OFF for 5 minutes
or decreases the conveyor speed as necessary to and then turned ON again.
match the speed setting shown on the thumbwheel
or display unit.

4
 SECTION 1 - SEQUENCE OF OPERATION
e. For ovens with an On-Off gas regulation sys- F. High Limit
tem (with solenoid valve): Temperature Controller NOTE: Most PS200-Series and PS360-series gas ov-
terminals 4 & 5 (power for the primary relay ens use the high limit feature of the Temperature Con-
contacts for the high flame solenoid valve). troller. All other oven models use a separate High Limit
For PS360EWB ovens with a modulating gas Control Module. Refer to the wiring diagram for the
system and Temperature Controller P/N 32571: appropriate oven model to check whether a separate
Temperature Controller terminals 4 & 5 (input High Limit Control Module is used.
signal to amplifier board). The high limit relay will shut the oven burner OFF:
For all other ovens with a modulating gas sys- 1. If the high limit thermocouple senses an oven tem-
tem: Temperature Controller terminals 15 & 16 perature above 650°F.
(input signal to amplifier board).
2. If the signal from the high limit thermocouple is
In all ovens, the temperature-sensing thermocouple(s) lost.
send a millivolt signal to the temperature controller. As
long as the temperature inside the oven is below the An indicator on the Temperature Controller will show a
set point of the Temperature Controller, the Controller high limit condition. This indicator varies by Tempera-
will do the following: ture Controller model. Refer to the instructions for the
appropriate Temperature Controller for an illustration and
1. For ovens with an On-Off gas regulation system: If description of this indicator.
the temperature sensed by the thermocouple(s) is
below the set point on the Temperature Controller, G. Cooldown
the Controller energizes the high flame solenoid. NOTE: PS200VL-series ovens do not include a
When the solenoid is energized, the solenoid valve cooldown feature.
permits 100% gas flow. Power to the solenoid is When the heat and blower Switches are turned OFF
cut when the temperature reaches the set point, the cooldown relay will allow the blowers to remain ON
which closes the valve. This permits on-off gas until the oven temperature falls to 200°F (93°C).
flow to the burner.
During cooldown, the Temperature Controller will con-
When power is cut to the high flame solenoid, the tinue to show the oven temperature.
burner will remain ON in the low flame mode. When
the temperature drops a few degrees, the Tempera-
ture Controller will again energize the high flame
solenoid, which opens the valve and restores gas
flow to 100%.
An indicator on the Temperature Controller will
show whether the high flame solenoid is energized
(or whether the burner is activated, which is effec-
tively the same). This indicator varies by Tempera-
ture Controller model. Refer to the instructions for
the appropriate Temperature Controller for an illus-
tration and description of this indicator.
2. For ovens with a modulating gas system: In re-
sponse to the signal from the thermocouple(s), the
Temperature Controller sends a 4-20mA signal to
the amplifier board. The amplifier board converts
this to a 0-20VDC signal which is sent to the modu-
lating gas valve. The valve opens or closes in pro-
portion to the signal from the amplifier board, al-
lowing the gas flow to be regulated as required from
0-100%.
An indicator on the Temperature Controller will
show whether the burner is activated. This indica-
tor varies by Temperature Controller model. Refer
to the instructions for the appropriate Temperature
Controller for an illustration and description of this
indicator.

5
SECTION 1 - SEQUENCE OF OPERATION
ll. ELECTRIC OVEN SEQUENCE OF OPERATION E. Heat Switch
A. Electrical Supply Closing the heat switch completes a circuit:
Most electrically heated ovens operate on a 208/230/ 1. Through the heat switch.
380/440V, 3 phase, 4 wire system. The fourth wire is 2. Through the blower motor centrifugal switch.
for a 120 V neutral ground. This 120 V neutral ground 3. Through the high limit switch.
eliminates the need for a control transformer. Where a
neutral is not available, a 240/110V transformer is sup- 4. For ovens with on On-Off heater activation mode:
To the primary relay contacts of the Temperature
plied.
Controller (terminals 4 and 5 for digital controllers,
B. Door Switch terminals 5 and 6 for analog controllers).
Closing the control cabinet door (or machinery com- When the temperature-sensing thermocouple(s)
partment door, as appropriate for the oven model) will indicate that the oven temperature is below the set
close the door switch and allow the oven to operate. point on the Temperature Controller, the Tempera-
Note that the electrical systems will still be “live” ture Controller will energize the contactor(s) which
if the switch is open, although the oven cannot in turn energize the heaters.
operate. When the oven temperature reaches the set point
of the Temperature Controller, the Temperature Con-
The door switch has a bypass position to enable ser-
troller will cut power to the heaters. When the tem-
vice operation with the door opened. When the door is
perature drops a few degrees, the Temperature Con-
open, grasp the switch actuator and pull it out as far as troller will again energize the heaters.
possible. This will close the door switch and permit
troubleshooting. Closing the control cabinet door will An indicator on the Temperature Controller will
show whether the Controller is calling for heat. This
reset the switch.
indicator varies by Temperature Controller model.
Closing the door switch permits a circuit to go through Refer to the instructions for the appropriate Tem-
a fuse (or circuit breaker, as appropriate for the oven perature Controller for an illustration and descrip-
model) to one side of the conveyor switch, blower mo- tion of this indicator.
tor switch and to the heat switch. 5. For ovens with a Variable Pulse heater activation
C. Conveyor Switch system: To terminals 15 and 16 on the tempera-
Closing the conveyor switch permits a circuit to go to ture controller. In response to the signal from the
thermocouple(s), Terminals 15 and 16 send a 4-
the Conveyor Speed Control Module, which:
20mA signal to a controller module that contains
1. Sends power to the gear motor (conveyor drive mo- an amplifier board and two solid state relays. The
tor). The 120VAC signal to the Conveyor Speed relays activate the heating elements at 100% power
Control Module is rectified to a 90VDC signal which on a fixed cycle time, for a length of time propor-
is then sent to the gear motor. tional to the signal from the temperature controller.
2. Allows regulation of conveyor speed. Adjusting the A “HEAT ON” indicator on the Temperature Con-
thumbwheel (or digital pushbutton display unit, as troller will light to show whether the Controller is
appropriate) to the desired conveyor belt speed in- calling for heat.
structs the Conveyor Speed Control Module to regu- F. High Limit
late the output to the gear motor. This increases NOTE: Electric oven models use a separate High Limit
or decreases the conveyor speed as necessary to Control Module.
match the speed setting shown on the thumbwheel
The High Limit relay will shut the oven burner OFF:
or display unit.
1. If the high limit thermocouple senses an oven tem-
D. Blower Switch
perature above 650°F.
Closing the blower switch energizes:
2. If the signal from the high limit thermocouple is
1. The cooling (axial) fan(s). lost.
2. The blower motor contactor (s). An indicator on the Temperature Controller will show a
Closing this contactor starts the blower motor(s). When high limit condition. This indicator varies by Tempera-
both blower motors are up to speed, centrifugal ture Controller model. Refer to the instructions for the
appropriate Temperature Controller for an illustration and
switch(es) located inside the rear end of the motor(s)
description of this indicator.
(or air flow switch[es], as appropriate for the oven model)
will close, setting up the heat circuit. G. Cooldown
3. The Temperature Controller. When the heat and blower switches are turned OFF
the cooldown relay will allow the blowers to remain ON
until the oven temperature falls to 200°F (93°C).
During cooldown, the Temperature Controller will con-
tinue to show the oven temperature.
6
 SECTION 2 - AIR FLOW AND HEAT TRANSFER

SECTION 2
AIR FLOW AND HEAT TRANSFER
I. TYPES OF HEAT TRANSFER In Middleby Marshall conveyor ovens, the heat transfer from
Heat constantly moves from a warm object to a cold ob- conduction is greatly dependent on the customer’s product
ject. Heat moves in three different ways: thorough con- and cooking surface (pans, etc.). Likewise, the heat trans-
duction, through radiation, and through convection. fer from radiation is effectively constant, because the color
Middleby Marshall conveyor ovens use all three of these of the oven interior cannot be changed. For these reasons,
paths to cook the product. the best way to optimize heat transfer is by regulating the
convection air. This can be done in two ways:
• Conduction - Heat is transferred through surface con-
tact (such as pizza dough in contact with a pan). • Adjusting the blowers and blower speed to change the
quantity and velocity of air delivered onto the product.
• Radiation - Heat is transferred from light-colored ob-
jects to dark-colored objects. The darker the color of • Adjusting the air finger configuration to change the pat-
an object, the greater the amount of heat that it ab- tern in which the vertical columns of air are delivered to
sorbs. The lighter the color of an object, the greater the product.
the amount of heat that it reflects. Middleby ovens use II. BLOWERS AND BLOWER SPEED
light-colored interiors (aluminized or stainless steel, A. PS200-series ovens
depending on the oven model) to reflect as much heat
as possible to the product. PS200-series ovens have a single blower motor mounted
inside the machinery compartment, with a pulley on
• Convection - Heated air will transfer heat to objects the end of the motor shaft. A belt connects this pulley
with which it comes into contact. Unless the air flow is to another on the shaft of the blower fan. The air veloc-
controlled, hot air will rise and be replaced by cooler ity can be changed by using a larger or smaller pulley
air. Middleby Marshall ovens use blowers (one or two on the motor shaft, and changing the length of the belt
large fans, depending on the oven model) to force air to match the new pulley. See Figure 1.
through adjustable air fingers onto the product.
However, note that there are only two approved belt/
The intensity of the heat at the point at which it is sensed is pulley combinations for PS200-series ovens; one for
called temperature. The difference in temperature between 60Hz ovens, and one for 50Hz ovens. Field modifica-
the food product and the heat source - that is, the pan, tions to these approved combinations are not permit-
oven interior, or heated air, as described above - determines ted unless under the specific directions of the Middleby
the speed at which the heat flows. The greater the differ- Technical Service Department. Any changes to con-
ence in temperature, the faster the heat flows to the prod- vection air delivery MUST be made using the air fin-
uct. gers.

Figure 1
Blowers, belts and pulleys

PS200-series PS360-series PS555/570-series

Early
(PS570)

Current
(PS570S,
PS570G, all
PS555)

Blower
Wheel Blower Wheel
Orientation Orientation
7
SECTION 2 - AIR FLOW AND HEAT TRANSFER
B. PS360-series ovens III. AIR FINGERS
PS360-series ovens feature two blower motors. A blower A. Description and Function
wheel is fastened onto the end of the motor shaft. In Air fingers direct the heated air from the blowers into
order to adjust the amount and speed of heated air that vertical jets that are directed at the top and bottom of
is directed by the blower wheels, it is necessary to the conveyor belt. Each air finger configuration has
change the size of the wheels and/or change the speed been tested to optimally cook a specific customer’s
of the motor. See Figure 1. product. As a rule, air finger configurations should NOT
Each PS360-series oven model has a specific combi- be changed from customer specifications without di-
nation of blower motor and blower wheel. Field modifi- rect instructions from the Middleby Technical Services
cations to these approved combinations are not per- Department.
mitted unless under the specific directions of the Middleby uses two main types of air fingers:
Middleby Technical Service Department. Any changes
to convection air delivery MUST be made using the air • PS300/350 and early PS310/360 ovens used a shut-
fingers. ter-type air finger assembly. The finger is as-
sembled from a manifold, inner plate and outer
C. PS555/570-series ovens plate. The inner plate is assembled from two sepa-
PS555/570-series ovens have one blower motor rate plates, each with a series of holes, that are
mounted inside each of the end compartments of the riveted together. The plates can be repositioned
oven, with a pulley on the end of the motor shaft. The relative to each other to restrict the air flow through
oven has two blower wheels; a belt connects each motor the holes as necessary. These fingers are no longer
pulley to a pulley on the end of one of the blower wheel in general use, but may still be found in older ov-
shafts. The air velocity can be changed by using a ens in the field. See Figure 3.
larger or smaller pulley on the motor shaft, and chang- • All current ovens use an air finger which is com-
ing the length of the belt to match the new pulley. See posed of a manifold, inner plate, and outer plate.
Figure 1. No adjustments are necessary or possible to these
Some customers have a specific belt/pulley combina- fingers, but a wide variety of styles is available to
tion approved by Middleby Marshall, while others use a meet different customers’ baking needs. See Fig-
“standard” configuration. Field modifications to these ure 4.
approved combinations are not permitted unless under
the specific directions of the Middleby Technical Ser-
Figure 3
vice Department. PS300/350 air finger with shutter plate
Outer plate
Lower air fingers have wire
rack as shown to prevent
conveyor belt from rubbing
on outer plate.

Figure 2 Rivets
Air finger operation Inner plate

Hot air flow Shutter

from blower
wheel(s)
Manifold

Figure 4
Vertical Current standard air finger (all oven models)
columns of Outer plate
high-velocity Width and hole
hot air configuration varies.

Inner plate
Width and hole
configuration varies.
May have inner dam.
Manifold
Width varies to match inner
and outer plates. Baffle may
be solid, perforated, partially
perforated, or absent.
Several special shapes are
available to meet specific
customer needs.
8
 SECTION 2 - AIR FLOW AND HEAT TRANSFER
B. Configuration and Alignment 2. Check that the bake time and temperature settings
To ensure proper baking of the product, the air flow of the oven match the customer’s specifications.
MUST be properly aligned as it exits the air fingers. Most customers have an acceptable range for bake
time and temperature to allow for local variations in
Because air finger configurations are tested at the fac- altitude, humidity, etc.
tory for a specific customer’s product, severe bake prob-
lems related to the air fingers are rare. If you encoun- 3. If these checks fail to correct the problem, you
ter a problem, check the following: should perform a test bake to pinpoint the type of
baking problem that is present.
1. Check that the air fingers are properly assembled,
cleaned and free of obstructions. For the standard C. Performing a Test Bake
air fingers shown in Figure 4, a variety of styles are Before you attempt to correct any problem, please CON-
available for each of the three components. It is FIRM THAT THERE IS ACTUALLY A PROBLEM. It is
often possible to assemble these components in- extremely difficult to tell if an oven is baking unevenly
correctly, as they are designed to be modular. This by simply looking at a pizza with ingredients, espe-
will affect the quality of the bake. cially if the pizza is a large combination-type. Often,
If you need information on the correct air finger con- the ingredients and toppings themselves can cause an
figuration of the oven, check the following: uneven bake.
• 3D air finger label or card. Many current ov- The best way to check for an uneven bake is to make a
ens will have a three-dimensional drawing on test bake with a consistent, “predictable” product and
the front panel of the oven that shows the cor- then read it. We recommend using the customer’s
rect air finger configuration, as shown in Fig- dough (for a pizza product) OR a commercially-avail-
ure 5. Other ovens may have this information able pancake mix (for customers with a variety of prod-
on a laminated card attached to the oven. ucts). The pancake mix is generally more sensitive to
variations in temperature and thus provides more accu-
• Internal air finger chart. All Middleby ovens rate results than the dough test.
have a chart similar to the one shown in Figure
6 attached inside the machinery compartment When interpreting the results of the test, consistently
door. Note that if the air finger configuration uneven baking on the top of the product may indicate a
has been updated since the oven was installed, problem with the upper air fingers. Likewise, consis-
this chart may no longer be correct. tently uneven baking on the bottom of the product may
indicate a problem with the lower air fingers.
• If there is no label present on the oven, and the
chart inside the machinery compartment is in- The most common bake problem is a “front-to-back”
correct, contact Middleby Technical Service for bake issue. This problem occurs when the “front” of the
assistance. conveyor belt (towards the window) receives more heat
than the rear, or vice-versa. This results in uneven bak-
ing for the product based on where it is placed on the
conveyor.
Figure 5 Figure 6
3D air finger label (if present) Internal air finger chart

NOTE: All ovens use a chart of this

type inside the machinery compartment.
NOTE: Labels of this type are not
used on all ovens. Label placement Changes to the air finger configuration
and design will vary based on after oven installation MAY NOT BE
customer preference. INDICATED.

9
SECTION 2 - AIR FLOW AND HEAT TRANSFER
To perform the test bake: Figure 7
1. Select identical pans for the test. Choose the pans Front-to-back uneven bake
based on the width of the conveyor; you should space
the pans in line completely across the conveyor with-
out having them touch each other. For instance, for a
32” /813mm-wide conveyor, you could use three 10”/
254mm pans or two 15”/381mm pans.
You will need enough pans to have three complete rows.
This eliminates the possibility of a single row distorting
the results. If necessary, the test can be run with only
1 row of pans, but the results are not as reliable.
2. For a pancake batter test, mix the pancake batter as
instructed by the manufacturer. Pour the batter
EVENLY into the test pans to a depth of 1/4” (6mm).
You may use any type of pancake mix that is available,
AS LONG AS YOU USE THE SAME TYPE THROUGH-
OUT THE TEST.
For a dough test, have the customer make up a thin
crust dough in each pan. The dough should be of a
consistent thickness in each pan and should be no NOTE: In this example,
the front of the product
thicker than 1/4” (6mm). Thicker doughs will provide is darker than the rear.
too great a “cushion” and will distort the test results. The opposite condition
is also possible.
3. Place the pans side-by-side on the conveyor. The front
and rear edges of the pans should be aligned so that it
is easier to see if there is a front-to-back bake prob- Finger Shutter Adjustment.”
lem. DO NOT stagger the rows of pans diagonally. D. PS300/350 Air Finger Shutter Adjustment
Also, check that the pans do not touch each other;
Before attempting to properly balance a Middleby
this can transfer heat to the test product and distort
Marshall oven equipped with shutter fingers, you should
the results.
understand the principles of operation of this type of
4. Run the products through the conveyor at the finger.
customer’s normal bake time and temperature settings.
The oven moves approximately 2000 ft.³ of air per minute.
5. “Read” the results of the test. Each pan of product When this large amount of air is moved through the
should have the same coloration. plenum and fingers it rushes through the plenum and to
If you used pancake batter, the sugar in the mix will the end of the air finger. This creates a back pressure
brown very rapidly if over-baked. This highlights an out- of air inside the finger and tends to deliver more air onto
of-balance oven. the product at the front of the air finger.
If the product lightens or darkens slightly from front-to- The inner plate has a separate shutter plate riveted to it
back in only one row, there is probably not a significant at a slight angle. Since there is more pressure at the
front-to-back bake problem. If the product is notice- end of the fingers (front of the oven) than at the plenum
ably lighter or darker at the front or back in ALL of the (rear of the oven), the shutter plate is angled to restrict
rows of pans, there is a front-to-back bake problem. the air flow near the front of the oven. This creates a
See Figure 7. proper balance permitting an even amount of air to exit
out of the holes across the width of the conveyor. See
Also, remember that consistently uneven baking on
Figure 8.
the top of the product may indicate a problem with the
upper air fingers. Likewise, consistently uneven bak- Before adjusting the shutters, it is necessary to deter-
ing on the bottom of the product may indicate a prob- mine if the finger is providing a balanced air delivery
lem with the lower air fingers. across the width of the conveyor. This is the purpose
• If the oven has the current standard air finger type,
you should contact Middleby Technical Services
for assistance.
• If the oven has the PS300/350-style air fingers with
a shutter plate, it is possible to adjust the posi-
tions of the air shutters to correct a front-to-back
bake problem. Proceed to Step D, “PS300/350 Air

10
 SECTION 2 - AIR FLOW AND HEAT TRANSFER
of making a test to ”read” the bake. point of the opening. See Figure 8.
1. Remove all upper air fingers from the oven. 5. While holding the new adjustment, clamp the two shut-
NOTE: As the air fingers are removed, use a felt pen to ter plates together (two pairs of vice grip pliers are ideal)
mark all parts of the fingers. This includes the mani- and drill holes for new pop rivets.
fold, inner plate and outer plate. If a blank or choke NOTE: Most of the old rivet holes can be reused if the
plate is used, mark that plate also. Fingers are marked old hole is simply elongated. However, if the hole is not
in the order shown below, as viewed from the front of properly elongated, the new rivets may pull the plates
the oven. If there are upper and lower oven cavities, out of adjustment when they are installed.
you should mark the fingers for the upper oven with a IMPORTANT: Aluminum 1/8” pop rivets are ideal
“U” and those for the lower oven with a “L.” for use here. They are much easier to drill out
VERY IMPORTANT: When the ovens were shipped than stainless steel rivets.
from the factory, all of the shutters were pre-ad- 6. Repeat these steps to adjust all upper air fingers. Then,
justed for their location within the oven. AII parts reinstall the fingers into the oven.
of the fingers must be marked as explained above
and reassembled into their original position. 7. Perform another test bake.

2. Check the size of the openings at the front of the shut- lMPORTANT: This test bake must be an exact dupli-
ter plates by inserting a drill into the opening. The cate of the first test bake. If you change any of the
factory setting is a #46 drill (0.081”/2.06mm). conditions you will change the results.

3. Drill out the four 1/8” pop rivets that are located toward • If the test indicates an even bake, your adjustment
the front of the fingers. See Figure 8. is complete.

NOTE: DO NOT drill out the rivet at the back of the air • If the test indicates that the bake is still uneven,
finger. This is the pivot for the shutter. you will need to repeat the adjustment procedure
until an even bake is obtained. By keeping the
4. If the product is lighter at the front of the oven, increase tests identical, you should be able to determine
the opening by 1/16”/1.59mm. If the product is darker how much more the shutter plates should be opened
at the front of the oven, decrease the opening by 1/16”/ or closed to achieve a balanced bake without re-
1.59mm. moving the fingers for a third time.
The best way to check the size of the openings is to VERY IMPORTANT: After attaining a proper adjust-
use numbered drills as a gauge. An orifice drill set is ment of the fingers, each air finger should be marked
ideal for making this adjustment. For example, to in- with a metal stamp showing its position inside the oven.
crease the opening by 1/16”, you would use a #30 drill This will eliminate future problems of operators mixing
(0.1285”/3.26mm), which is approximately 1/16” larger the adjusted fingers when cleaning the oven.
than the original setting measured with the #46 drill
(0.081”/2.06mm).
Be sure that the measurement is taken at the largest

Figure 8
PS300/350-style air finger with adjustable shutter plate
Insert drill bit
to check size
Pivot
of opening
DO NOT
drill out Drill out
rivets

Vise grip
pliers

Higher pressure at the

front of the fingers is
regulated by the
shutter openings
11
SECTION 2 - AIR FLOW AND HEAT TRANSFER
IV. OVEN CAPACITY B. Belt Time
Oven capacity is generally not a service issue. However, Belt Time is a measurement used by several custom-
when reporting a service problem, customers may use terms ers. It is a trailing edge to trailing edge measurement.
relating to capacity, such as bake time, belt time, time of That is, it is the elapsed time from the trailing edge of
delivery, etc. This information is provided as a reference for the product entering the bake chamber to the trailing
understanding these terms. edge of the product leaving the bake chamber. See
A. Conveyor Speed and Bake Time Figure 10.
Middleby Marshall conveyor ovens display the Conveyor Note that belt time is equal in length to conveyor speed
Speed on the Thumbwheel (or on the display of the (bake time), although the time is measured during a
Digital Speed Controller, as appropriate for the oven different period of the baking process.
model). Conveyor Speed is also called Bake Time. C. Time of Delivery (TOD)
Conveyor Speed (Bake Time) is a leading edge to lead- Time of delivery (TOD) is a leading edge to trailing edge
ing edge measurement. That is, it is the elapsed time measurement. That is, it is the elapsed time from when
from the leading edge of the product entering the bake the leading edge of the product enters the bake cham-
chamber to the leading edge of the product leaving the ber to when the trailing edge of the product leaves the
bake chamber. See Figure 9. bake chamber. See Figure 11.

Figure 9 - Conveyor Speed (Bake Time) Figure 10 - Belt Time

Conveyor Speed Belt Time
(Bake TIme)

Direction of Direction of
Conveyor Travel Leading edge Trailing edge Conveyor Travel
of product of product

Figure 11 - Time of Delivery

Time of Delivery

Direction of
Conveyor Travel

Leading edge Trailing edge of

of product product

D. Formulas for Determining Time of Delivery (TOD) and Oven Capacity per Hour
1. Time of Delivery (TOD)
Conveyor Speed
Time of Delivery (TOD) = x (Bake Chamber Length + Product Diameter)
Bake Chamber Length
7 mins.
Example: PS570S Oven, 7:00 Bake Time, 16” Product Diameter = x (70” + 16”) = 8.6 mins. (8:36)
70”

2. Oven Capacity/Hour
(Bake Chamber Length + Product Diameter) x Bake Chamber Depth 60 min./hr.
Oven Capacity/Hour = x
Product Diameter² TOD
(70” + 16”) x 32”
Example: PS570S Oven, 7:00 Bake Time, 16” Product Diameter = x 6.98 = 75 pizzas/hr.
256 in.²

12
 SECTION 3 - SERVICING COMPONENTS

SECTION 3
SERVICING COMPONENTS
I. CONVEYOR SPEED CONTROLLER AND DRIVE A. Part Number Reference - Speed Controllers
MOTOR 1. Original-style speed controller with interchangeable mi-
The Conveyor Speed Controller is used to set and monitor crocomputer and thumbwheel. This unit is no longer
the speed of the conveyor. The Controller consists of three available and part numbers are provided for reference
components: only. Servicing this unit is beyond the scope of this
• Control Module manual. If this controller is in need of service, we rec-
ommend simply installing a current unit (see below).
Early units used a module which featured a microcom-
P/N Description
puter that was unique to each oven model. Using this
28174-0004 PS360 controller, yellow (12A) microcomputer
control module required verifying that the correct mi-
28074-0006 PS360 microcomputer, yellow (12A)
crocomputer was installed. 27170-0232 PS360 microcomputer w/emulator, yellow (12A)
Later units use DIP switches to set up the controller for 28074-0007 PS314 controller, orange (13A) microcomputer
a particular oven model. This later model was initially 28074-0008 PS314 microcomputer, orange (13A)
available with a thumbwheel unit (either 4 or 8 DIP 27170-0233 PS314 microcomputer w/emulator, orange (13A)
switches). Current models feature a digital display with 28074-0013 PS200 microcomputer, pink (15A)
keypad (8 DIP switches). 2. Current-style speed controller with either 4 or 8 DIP switch
• Thumbwheel Unit (or Digital Display with Keypad) settings and thumbwheel. This unit is no longer available
This module displays the conveyor speed and allows it from the factory, but may still be stocked by service agen-
to be adjusted by the operator. It is connected to the cies.
control module by a ribbon cable. P/N Description
42810-0133 Controller assembly with thumbwheel
• Pickup Assembly
42810-0118 Thumbwheel only
The pickup assembly consists of a magnetic wheel on
the end of the gear motor (conveyor drive motor) shaft, 3. Current-style speed controller with 8 DIP switch set-
and a Hall Device sensor that provides feedback to the tings and digital display/keypad. Note that the two types
control module. of controllers ARE NOT compatible - the controller and
display unit MUST be of the same type.
As the magnetic wheel turns, the revolutions of the
P/N Description
magnet are monitored by the Hall Device sensor. The
37337 Controller assembly with digital display/keypad,
signals are sent to the control module, which compares NCC (8/00-current)
the motor speed with the speed shown on the 37503 Digital display/keypad unit only, NCC
thumbwheel or digital display. The control module in- 45133 Controller assembly with digital display/keypad,
creases or decreases the voltage to the gear motor Danaher (2/02-current)
(conveyor drive motor) depending on the signal.

Figure 12 Figure 13
Original-style speed controller Current-style speed controller
Produced with thumbwheel only. Produced with Thumbwheel or digital display.
Interchangeable microcomputer selects oven model. 4 or 8 DIP switches select oven model.
THIS CONTROLLER IS OBSOLETE AND NO DIP switches may Cover plate
LONGER AVAILABLE. be on control shows DIP
module or digital switch settings
Control module display, depending
Microcomputer
on the controller
Thumbwheel
model.
or digital
display

Control
module

Thumbwheel
13
SECTION 3 - SERVICING COMPONENTS
B. Part Number Reference - Pickup Assemblies Figure 14
1. PS350-style pickup assembly or old-style pickup as- PS350-style pickup assembly
sembly (see Figures 14-15). These parts use the same (used on early PS360)
part number. They are no longer available from the
factory, but may still be stocked by some service agen-
cies.
P/N Description
28074-0005 Pickup assembly, PS350-style or old-style

2. Current-style pickup assembly (see Figures 16-17)

P/N Description
27170-0263 Pickup assembly, current

C. Preparing to Service the Speed Controller

NOTE: To properly service this equipment, you must use a
digital meter. An analog meter will not work.
1. Before troubleshooting the conveyor speed controller,
check the following:
a. Conveyor belt is tight.
b. Drive chain is tight and aligned.
c. Set screws on drive sprockets are tight.
Figure 15
d. Axial fan(s) are running and clean of dust and de-
bris. Old-style pickup assembly
e. Motor and pickup wires are secure at the Conveyor
Terminal Block (location of the block varies by oven
model).
f. Wire connections on conveyor speed control mod-
ule (including the ribbon cable to the thumbwheel/
display unit) are secure.
2. Check the pickup for the following (see Figures 14-17):
a. Pickup is secure.
b. Magnet is not cracked or chipped.
c. Magnet is not rubbing on plastic housing.
d. Mounting bolt is not worn or bent.
e. Pickup bearing in good condition.
f. On PS350-style pickup (Fig. 14), gap between
magnet and Hall Device is spaced approximately
1/64”-1/32” (0.4-0.8mm, or a business card thick-
ness).

14
 SECTION 3 - SERVICING COMPONENTS

Figure 16 Figure 17
Current pickup assembly - side view Current pickup assembly -
end view

D. Controller/Motor Failure Components needed for the field tester:

When the conveyor speed controller fails, it is very pos- • Full-wave AC-DC bridge, 400V, 4A
sible that a shorted conveyor motor caused the problem. • Light dimmer switch, 5A
Unless the motor is changed, the installation of another • In-line 5A AC fuse enclosed in plastic case
conveyor speed controller will simply burn up the new con- • 2 alligator clips
troller.
CAUTION: DO NOT turn the conveyor switch ON while
You are STRONGLY ADVISED to bypass the speed con-
the field tester is connected!
troller and install the tester unit shown in Figure 18 before
replacing any speed controller that has burned out. This 1. Disconnect the motor lead wires and attach to the field
will identify the source of the problem - the speed controller tester as shown in Figure 18. Depending on the oven
or the motor. It is much less expensive to burn out the model, you can simply use the black and red gear motor
tester than another speed controller. leads, or the remote leads at the terminal block con-
nection.
The components for this tester can be purchased at any
electrical supply store. The tester is not as accurate or To reverse the conveyor motor direction, simply inter-
sensitive as the speed controller, and so should NOT be change the black and red leads.
left in place on the oven after servicing! 2. To start the test, the dimmer switch should be turned
until the motor begins to operate. The switch can then
be turned down to the desired motor speed.

Figure 18
Field Tester for Conveyor Drive Motor

or circuit breaker

15
SECTION 3 - SERVICING COMPONENTS
E. Basic Troubleshooting Flowcharts

1. IF THE GEAR MOTOR RUNS AT FULL SPEED:

NOTE:
Middleby no longer stocks parts for the original
speed controller with interchangeable microcom-
puter. If it is necessary to replace this version of
the controller or the microcomputer, and the
service agent does not have the parts in stock, it
will be necessary to replace the entire speed
controller with a current model.
16
 SECTION 3 - SERVICING COMPONENTS

2. IF THE GEAR MOTOR WILL NOT RUN AT ALL:

NOTE:
Middleby no longer stocks parts for the
original speed controller with inter-
changeable microcomputer. If it is
necessary to replace this version of
the controller or the microcomputer,
and the service agent does not have
the parts in stock, it will be necessary
to replace the entire speed controller
with a current model.
17
SECTION 3 - SERVICING COMPONENTS
F. Initial Troubleshooting 3. With the AC power on,
NOTE: When changing the conveyor speed on a controller check the DC voltage to
with a thumbwheel, it is advisable to turn the conveyor switch the conveyor motor.
OFF before adjusting the thumbwheel. Note that this can- Match the measured volt-
not be done on a digital keypad, as switching the conveyor age with those shown on
switch OFF will also turn off the display. the chart below. If the
voltage reading is more
1. Check all connections at the terminals on the conveyor than ±5VDC of that shown
speed control module to ensure that they are correct on the chart, complete
and tight. Connections are shown in the drawing. the Motor Test on the next
Correct the connections if necessary. page.

Connections are
reversed if
conveyor direc-
tion is reversed.
120VAC supply. Thumbwheel/ DC Motor Voltage
Wire colors vary Display PS200, PS310, 360,
by oven model. Setting 570, 360WB70 360WB, 360EWB
3 mins. 84VDC 67VDC
4 mins. 63VDC 50VDC
5 mins. 51VDC 40VDC
6 mins. 43VDC 34VDC
7 mins. 37VDC 28VDC
8 mins. 32VDC 25VDC
9 mins. 29VDC 22VDC
10 mins. 27VDC 20VDC
11 mins. 24VDC 18VDC
12 mins. 22VDC 17VDC
13 mins. 19VDC 14VDC
15 mins. 18VDC 13VDC
2. Ensure that there is power to the controller. Use a
digital multimeter to read the voltage between the ter-
minals marked “AC.” The voltage should read between
4. Check the magnetic
110-120VAC.
pickup on the motor.
If the power is not present or of an incorrect voltage,
If the pickup is in good
check the power source.
condition, check that
the conveyor is running
and then check the volt-
age between the “COM
and “±5VDC” terminals
on the controller. On
controllers with thumb-
wheels, the voltage
should read 5VDC,
±0.3VDC. Digital con-
trollers should read
5VDC , ±1.0VDC.
Next, check the voltage
between the “COM”
and “COUNT” terminals. The reading should stay be-
tween 2 and 3VDC.
If EITHER of these two readings are incorrect, perform
the Conveyor Control Pickup Test on the next page.

18
 SECTION 3 - SERVICING COMPONENTS
G. Conveyor Control Pickup Test H. Conveyor Motor Test
1. Visually check the pickup for the following: 1. Disconnect the gear motor wires from the Speed Con-
• The magnet is clean and the bearing is in good troller terminals (“-ARM” and “+ARM”).
condition. 2. Remove the brush retainer caps from the gear motor.
• There are no chips or cracks on the magnet. DO NOT remove the brushes.
• If using a PS350-style pickup (see Figure 14), there 3. Set the multimeter to the lowest Ohm scale. Then,
is a 1/64” to 1/32” (0-4-0.8mm, or a business card place one meter probe on each brush retaining plate.
thickness) gap between magnet and hall device. BE SURE THAT NEITHER PROBE TOUCHES THE
MOTOR CASING.
2 Set the multimeter to the VDC scale, then connect the
meter probes as shown in Figure 19. The black (-com- 4. Using a 5/16” open-end wrench, very slowly rotate the
mon) probe should connect to the “COM” terminal on motor pickup shaft while observing the multimeter. Dur-
the speed control board, while the red (+VW) probe ing a 1/2 rotation:
connects to the “+5V” terminal. +5VDC should be • The Ohm reading should stay betweeen 3-5W.
present at all times when the conveyor is operating. • There should NEVER be a complete short.
• If +5VDC is present, proceed to Step 3. • There should never be a high Ohm reading.
• If +5VDC is not present, disconnect the three pickup If the motor fails any of these tests, replace the motor.
wires (connected to the “COM,” “SIGNAL,” and “+5V”
terminals) and again check for +5VDC. I. Replacing the Magnetic Pickup
- If +5VDC is present with the pickup discon- If you need to replace the magnetic pickup on a gear motor
nected, replace the pickup assembly. shaft:
- If +5VDC is still not present, replace the con- 1. Apply Loctite Removable #242 (or equivalent) sparingly
veyor speed controller. to the threads.
3. Connect the multimeter’s red (+) lead to the “SIGNAL” 2. Turn the mounting screw until it is finger tight, then turn
terminal; then, disconnect the motor wires from the “- it an additional 1/4 turn with a wrench.
ARM” and “+ARM” terminals. Using a 5/16” open-end
wrench, very slowly rotate the motor pickup shaft while J. Unshielded Pickup Wires on Early PS360-series ovens
observing the multimeter. Two (2) changes from +5VDC The conveyor speed controller can be affected by electrical
to 0VDC should occur for each motor revolution. noise transmitted by other electrical components or wiring.
• lf the signal is always at 0VDC, go to Step 4. Early PS360-series ovens used an unshielded connection
• lf the signal is always at 5VDC, OR if the signal between the pickup assembly and the control module. On
changes more than 2 times per revolution, replace these ovens, the unshielded wiring can pick up the noise
the pickup assembly. and transmit it to the control module. The problem is most
easily seen when the conveyor fails during burner spark
4. Disconnect the pickup signal wire from the speed con- ignition.
troller and check for +5VDC at the “SIGNAL” terminal of
There are two remedies for this problem:
the controller.
1. Turn the conveyor switch to the OFF position, and then
• If +5VDC is present, replace the pickup assembly.
back to the ON position, after the burner has ignited.
• If 0VDC is present, replace speed control. The controller should reset and allow normal operation.
Figure 19 This should be used as a stop-gap measure ONLY to
Connections for pickup test allow the oven to continue operation.
2. Replace the pickup wiring between the control module
and the terminal block with a new shielded cable (P/N
42400-0334). When installing the shielded cable, fol-
low the color code change shown here:
Old Wiring Shielded Cable
Brown Black
Orange Red
Ye l l o w White
Wiring diagrams are also provided in Figures 20 and 21
on the next page.
There is a fourth lead on one end of the shielded cable.
This is a ground lead which is attached to the black
wire of the cable. The ground lead should be connected
to the terminal block inside the motor compartment.
Current PS360-series ovens have the shielded cable
installed at the factory and do not require this retrofit.
19
SECTION 3 - SERVICING COMPONENTS

Figure 20
Wiring for PS360 Shielded
Pickup Cable - early terminal
block design

Figure 21
Wiring for PS360 Shielded
Pickup Cable - late terminal
block design

K. Appendices

Appendix - Conveyor sensor wiring changes for PS360-series and PS570S, 10/95

20
 SECTION 3 - SERVICING COMPONENTS

Appendix - Service Bulletin MM-133B - Installation Instructions for Conveyor

Speed Controller Kit with Thumbwheel, P/N 42810-0133, 4/95

21
SECTION 3 - SERVICING COMPONENTS

Appendix - Service Bulletin MM-133B - Installation Instructions for Conveyor

Speed Controller Kit with Thumbwheel, P/N 42810-0133, 4/95

22
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 42810-0133-

Conveyor Speed Controller Kit with Thumbwheel, 4/95

23
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 42810-0133-

Conveyor Speed Controller Kit with Thumbwheel, 4/95

24
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 42810-0133-

Conveyor Speed Controller Kit with Thumbwheel, 4/95

25
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 42810-0133-

Conveyor Speed Controller Kit with Thumbwheel, 4/95

26
 SECTION 3 - SERVICING COMPONENTS

Appendix - Service Bulletin MM-177 - Introduction and Compatibility of

Conveyor Speed Controller with Digital Display, P/N 37337, 8/00

Bulletin No. MM-177

Date: 8/18/00

Middleby Cooking Systems Group

1400 Toastmaster Drive • Elgin, IL 60120-9272 U. S. A. • Telephone: (847)741-3300 • Service and Parts Fax: (847)741-4406

Service Bulletin
SUBJECT
Availability of Conveyor Speed Controller Kits

GENERAL
Middleby Marshall is changing is standard Conveyor Speed Controller from the familiar thumbwheel
control to a unit that features a digital display with pushbutton speed selectors. The part numbers of
these components are summarized here:
Speed Controller with Thumbwheel
• Kit (includes control module and thumbwheel): 42810-0133
• Thumbwheel unit only: 42810-0118
Speed Controller with Digital Display
• Kit (includes control module and digital display): 37337
• Digital selector/display unit only: 37503
Because of this change, supplies of the previous speed controller are VERY LIMITED, and the sepa-
rate thumbwheel is no longer available. Immediately stock the new Speed Controller units and save
your remaining thumbwheel controls for use with the oven models that cannot use the new controller.

APPLICATION
• Service agents should immediately begin to stock P/Ns 37337 and 37503 to fulfill their normal
need for conveyor speed controllers. The new units can be used without modification on ALL
OVENS EXCEPT THE PS200R68-SERIES.
• Your existing stock of P/Ns 42810-0133 and 42810-0118 should be used, whenever possible,
ONLY for PS200R68-series ovens.
• The new speed controller and digital display are already in use on Middleby Marshall PS555 ovens;
so, your Agency may already have some of these components in stock. Please check your exist-
ing stock of these components before placing addtional orders.

COMPATIBILITY
The Speed Controller with Digital Display is compatible with all Middleby Marshall ovens EXCEPT the
PS200R68, PS220R68, and PS224R68.

AVAILABILITY
• P/Ns 37337 and 37503 are available for immediate shipment.
• P/N 42810-0133 is available in very limited quantities. Note that some future orders may not be
fulfilled.
• P/N 42810-0118 is no longer available.

27
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 44756 - Conveyor Speed Controller Kit
for PS200R68-series Ovens, 2/02

Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • USA • (847) 741-3300 • FAX (847) 741-4406

Instructions for Service Kit 44756

Conveyor Speed Controller Kit for PS200R68-series ovens
KIT COMPONENTS:
Qty. P/N Description
1 37337 Conveyor speed controller with digital display
1 44749 Cable assembly, PS200R68-series ovens
1 44757 Instructions, PS200R68-series oven conveyor speed controller kit

This Service Kit will update one Middleby Marshall PS200R68, PS220R68, or PS224R68 oven to operate using the current
digital conveyor speed controller with keypad display (P/N 37337), instead of the previous controller with thumbwheel
adjustment (P/N 42810-0133). If the oven is already equipped with controller P/N 37337, this Kit is not necessary; P/N 37337
may be used as a direct replacement for the existing controller.

WARNING
BEFORE PERFORMING ANY SERVICE WORK, THE ELECTRICAL POWER SUPPLY AND THE GAS
SUPPLY MUST BE TURNED OFF.

1. Disconnect the oven from its electrical power supply at shown on the case of the controller and are also provided
the circuit breaker/fused disconnect. For gas ovens, in Figure 1.
shut off the gas supply to the oven.
9. Install the new module in place. Close and fasten the
2. Identify the 24-pin control cable (female at both ends) that machinery compartment door.
connects the rear of the remote box (on top of the oven) to
the rear of the machinery compartment (on the side of the 10. Temporarily remove the remote box from the top of the
oven). oven. Open the remote box.

3. Remove and discard the cable. 11. Disconnect the thumbwheel unit’s ribbon cable plug from
its socket on the remote board. Then, remove and dis-
4. Open the machinery compartment door and locate the card the thumbwheel unit.
conveyor speed control module.
12. Install the new digital display unit in place. Connect its
5. One at a time, disconnect the leads from the terminals on ribbon cable plug into its socket on the remote board.
the existing speed control module and connect them to
the corresponding terminals on the new control module. 13. Close the remote box and reinstall it atop the oven.

6. Remove the ribbon cable plug from its socket on the old 14. Install the new kit-supplied control cable between the back
speed control module, and attach it to the corresponding of the remote box and the back of the machinery compart-
socket on the new control module. ment.

7. Remove and discard the old control module from the in- 15. Restore the electrical and gas utility supplies to the oven.
side of the machinery compartment door. 16. Test the operation of the new conveyor speed controller to
8. Adjust the DIP switch settings on the new speed control make certain that it is operating properly. The oven is now
module to the correct settings for the PS200-series oven ready for operation.
with a 3-30 minute bake time range. These settings are

Figure 1
DIP Switch Settings

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 P/N 44757 • Rev. C • V1 • 2/02

28
 SECTION 3 - SERVICING COMPONENTS

Appendix - Service Bulletin MM-189 - New Conveyor Gear Motors,

Brushes, and Pickup Clamps, 8/01

Bulletin No. MM-189

Date: 8/24/01

Middleby Cooking Systems Group

1400 Toastmaster Drive • Elgin, IL 60120-9272 U. S. A. • Telephone: (847)741-3300 • Service and Parts Fax: (847)741-4406

Service Bulletin
SUBJECT
New conveyor gear motors, brushes, and pickup clamps for Middleby Marshall ovens

GENERAL
The conveyor gear motors used on all Middleby Marshall ovens (except model PS536) have been redesigned by the
vendor. Changes to the motors include:
• A smaller-diameter motor casing.
• New motor brushes.
- Old-style motors continue to use brush P/Ns 22450-0052 or 22450-0230 as shown in the table below.
- All of the new motors use brush P/N 46658.
• A shorter clamp to attach the pickup assembly. This accommodates the smaller diameter of the motor.
- The pickup assembly with the original clamp is still available as P/N 27170-0263. This kit is only available in
limited quantities. After our stock of the old-style pickup assembly kit is exhausted, you will need to save the
existing clamp to attach a new pickup assembly to an old-style motor.
- The pickup assembly with the new, shorter clamp is available as P/N 46451.
- All of the new motors will be shipped in a kit that also includes the new clamp. This allows you to attach an
existing pickup assembly to a new motor.
- In 7/01 and 8/01, some of the new motors were shipped under the part numbers of the old motors. These parts
shipped without the new clamp. In most of these cases, you can tighten the existing clamp to fit the new motor.
Some older clamps, however, cannot be tightened enough to fit. To be sure that you can install the new motor
in all ovens, you should add the new clamp, P/N 46602, to your required parts stocking list, and carry a few
spare clamps on each service vehicle.
Please be aware of these changes as you order your stocking parts. Some versions of the old motor, as well as the old-
style pickup assembly, are still available in limited quantities. The brush for the old motor (P/N 22450-0052) will remain
available in order to maintain motors already in the field.
Old Old Old New New New New
Ratio Used on Motor Brush Pickup Motor* Brush Pickup Clamp
1400:1 PS310 27384-0008 22450-0052 27170-0263 46603 46658 46451 46602
PS314
PS360/360S
PS360SS High Speed
PS360T Tandem
PS360WB
PS360WB70
PS360EWB
PS555
PS570/570S Single Belt
1350:1 PS200/220FS/224 27384-0011 22450-0230 27170-0263 46604 46658 46451 46602
PS200VL/220VL/224VL
PS200R68/220R68/224R68
PS200T Tandem
PS570/570S Split Belt (Standard)
600:1 PS314SBI 27384-0003 22450-0052 27170-0263 46605 46658 46451 46602
300:1 PS200/220FS/224 (High Speed) 27384-0014 22450-0230 27170-0263 46606 46658 46451 46602
PS570/570S Split Belt (High Speed)
* “New Motor” part numbers shown in this table are kits that include both the motor and the new pickup clamp.

29
SECTION 3 - SERVICING COMPONENTS

Appendix - DIP switch settings for Conveyor Speed Controller

with Digital Display (P/N 37337), 4/02

II. TEMPERATURE CONTROLLER For this operating mode, the temperature controller is set
The Temperature Controller is used to set and control the to the On-Off Mode as described in the Kit instructions.
oven temperature. Depending on the oven, model, the con- • On electric ovens with variable pulse heater activation
troller has several functions: (including PS555 electric ovens), the temperature con-
• On gas ovens with On-Off gas valve operation, the tem- troller sends its signal to a controller module that con-
perature controller opens and closes the high flame tains an amplifier board and two solid state relays. The
solenoid. This allows 100% or 0% gas flow to the burner relays activate the heating elements at 100% power on
in response for the need for heat to maintain the set a fixed cycle time, for a length of time proportional to
point temperature. The temperature controller has no the signal from the temperature controller.
effect on the low flame bypass or oven ignition. For this operating mode, the temperature controller is set
For this operating mode, the temperature controller is set to the PID Mode as described in the Kit instructions.
to the On-Off Mode as described in the Kit instructions.
• On gas ovens with modulated gas valve (PID) opera- Note that temperature controller P/N 46837
tion, the temperature controller sends a signal to the (inc. with Service Kit 47321) includes a dedi-
amplifier board which in turn controls the operation of cated variable pulse mode intended for the
the modulating valve. This allows a modulated gas flow PS536 electric oven. This special mode is NOT
of any necessary value from 0-100% in response for used on the PS555.
the need for heat to maintain the set point. The tem-
perature controller has no effect on oven ignition. • The temperature controller regulates the cooldown func-
For this operating mode, the temperature controller is set tion. NOTE: PS200VL-series ovens do not include a
to the PID Mode as described in the Kit instructions. cooldown function.

• On electric ovens with On-Off heater activation (includ- • On most PS200-series and PS300-series gas ovens
ing most PS200-series and PS360-series electric ov- (except the PS200VL), the temperature controller moni-
ens), the temperature controller permits or cuts power tors the high limit. All other oven models use a High
to the heating elements as necessary to maintain the Limit Control Module that is independent of the tem-
set point temperature. perature controller.

30
 SECTION 3 - SERVICING COMPONENTS
A. Part Number Reference - Temperature Controllers shown are no longer available and part numbers are pro-
Middleby Marshall ovens have used several different mod- vided for reference only. Servicing these units is beyond
els of temperature controllers. The current Digital Tem- the scope of this manual. If one of these controllers is in
perature Controller (P/N 46837, included in Service Kit 47321) need of service, we recommend simply installing a current
is the only model currently available. All other controllers unit (P/N 46837, included in Kit P/N 47321).

• P/N 28071-0012 (A) • P/N 30871 (E)

Analog Temperature Controller without high-limit and Digital Temperature Controller with gray rubber face
cooldown functions, 120V, on-off mode only. plate and buttons with symbols, 208-240V, on-off mode
• P/N 28071-0018 (A) only. Used on early PS360WB70 and some CE oven
Analog Temperature Controller with high-limit and models.
cooldown functions, 120V, on-off mode only. • P/N 32571 (E)
• P/N 34983 (B) Digital Temperature Controller with gray rubber face
Analog Temperature Controller without high-limit and plate and buttons with symbols, 208-240V, PID mode
cooldown functions, 120V, on-off mode only. Used on only. Used on early PS360EWB.
PS200VL-series ovens only. PS200VL-series ovens • P/N 36021 (F)
equipped with this Temperature Controller do not have Digital Temperature Controller with gray face plate (steel
a cooldown feature and use a separate high limit con- trim on edges), 120-240V, selectable on-off or PID
trol module. modes.
• P/N 28071-0027 (C) • P/N 36056 (G) - Service Kit P/N 36939
Digital Temperature Controller with blue plastic face- Digital Temperature Controller with black plastic face
plate, 120V, on-off mode only. plate, 120-240V, selectable on-off or PID modes.
• P/N 28071-0028 (D) • P/N 46837 (G) - Service Kit P/N 47321
Digital Temperature Controller with gray rubber face- Digital Temperature Controller with black plastic face
plate and buttons with text, 120V, on-off mode only. plate, 120-240V, selectable on-off, PID and variable
• P/N 28071-0028 (E) pulse modes.
Digital Temperature Controller with gray rubber face Note that the dedicated variable pulse mode is used on
plate and buttons with symbols, 120V, on-off mode only. the PS536 electric oven ONLY. Using this mode re-
quires moving a jumper on one of the PC boards inside
the controller. The PS555 variable pulse electric oven
does NOT use this mode and should have the control-
ler set to the PID mode as described in the Kit instruc-
tions.

Figure 22 - Temperature controllers

A B

C D E F G

31
SECTION 3 - SERVICING COMPONENTS
B. Description D. Troubleshooting
The temperature controller consists of two main compo- 1. Troubleshooting the Temperature Controller and
nents: a sleeve or case (metal or plastic) with terminal con- Thermocouple(s) using the Altek Thermocouple Source
nections on the back, and a plug-in chassis that includes (Middleby P/N 27170-0192)
the faceplate and circuitry. The sleeve is mounted to the • Turn the heat switch OFF.
panel or door of the oven, and the chassis is inserted into • Disconnect the thermocouple leads from Terminals
the front of the sleeve. 7 and 8 on the temperature controller. Tape the
VERY IMPORTANT: When replacing a controller, you ends to prevent shorting.
should ALWAYS replace the sleeve as well. Some control- • Connect the white lead of the Thermocouple Source
ler models have sleeves of a similar size, but with DIFFER- to Terminal 8 (+). Connect the red lead of the Ther-
ENT CONNECTIONS. Using an incorrect sleeve can dam- mocouple Source to Terminal 7 (-).
age the controller and cause the oven to function incor- • Set the Thermocouple Source as close as pos-
rectly. Exception: The sleeve used on Controllers 36056 sible to the customer’s set point. Then, turn the
and 46837 is identical except for the information label. BLOWER switch to the ON position.
C. High Limit/Cooldown Functions The temperature controller should read close to the
Except where noted in Section A (Part Number Reference), customer’s set point. Failure indicates a problem with
the temperaturecontroller incorporates circuitry for the high the temperature controller. If the temperature control-
limit and cooldown functions. ler is functioning properly, check the thermocouples.
1. The High Limit function (terminals 11 and 12) will shut Refer to Section IV, Thermocouples.
off the burner/heating elements if the oven temperature 2. Troubleshooting the High Limit Switch
sensed by the thermocouple(s) exceeds 650°F/343°C. On ovens that use the high limit function of the tem-
This function is used on most PS200-series and PS360- perature controller (most PS200-series and PS360-se-
series gas ovens. All other oven models use a sepa- ries ovens), an intermittent high limit switch will cause
rate high limit control module. intermittent operation of the burner. If you suspect that
If the high limit temperature is reached, an indicator on this is a problem, a good check is to place a 1A fuse in
the controller will illuminate. The current controller parallel around the switch contacts (terminals 11 and
(P/N 46837) has a lamp marked “OVERTEMP” to show 12).
this condition. Older controllers will have different indi- If the switch is functioning properly, the fuse will never
cators; you should refer to the operating instructions carry a load. The only time the switch would open
for the controller in question for assistance. would be under a no-load condition.
2. The Cooldown function allows the blowers to continue If the switch is trying to open intermittently, however,
in operation after the operator switches off all operating the full current load of the blowers will be carried by the
switches on the control panel. The blowers will remain fuse. Regardless of the oven model, this load is far
in operation until the cooldown switch opens (usually greater than 1A, and the fuse will blow.
180°F/82°C).
E. Appendices
Appendix - Temperature controller terminal cross-reference, 4/02
Terminal for Terminal for
28071-0012 and Terminal for 36056 and Description
28071-0018 34983 46837
1 TC+ 8 + TC
2 TC- 7 - TC
5 COM 5 Input to Temperature Control Relay
6 NO 4 Output to High Flame Solenoid or Heater Contactors
L2 L2 L2 Neutral
L1 L1 L1 Power
G G Ground
13 -- 9 Input to Cooldown Relay
14 -- 10 Output from Cooldown Relay
15 -- 11 Input to High Limit Relay
16 -- 12 Output from High Limit Relay
-- -- 15 PID or Variable Pulse Output
-- -- 16 PID or Variable Pulse Output

32
 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 • USA • (847) 741-3300 • FAX (847) 741-4406

Instructions for Service Kit 47321

Digital Temperature Controller

Installation, Programming and Troubleshooting Instructions

KIT COMPONENTS
Qty. P/N Description
1 46837 Digital Temperature Controller (On/Off Gas & Electric, PID Gas, and
Variable Pulse Electric operating modes), with mounting brackets
1 47322 Instructions

TABLE OF CONTENTS
Controller Types ............................................................................................... 2
Before You Begin ............................................................................................. 3
Installation ........................................................................................................ 3
Electrical Connections ..................................................................................... 4
Jumper Setting ................................................................................................. 6
Programming ................................................................................................... 6
Diagnostic Error Messages ............................................................................. 8
Operating Instructions (to be left with customer after installation) ...................... 9

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
© 2002 Middleby Marshall. P/N 47322 • Rev. A • V2 • 2/02
Page 1 of 10

33
SECTION 3 - SERVICING COMPONENTS

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

Controller Types
This Kit includes one Digital Temperature Controller (P/N 46837) that can operate at 120-240V, and
can be programmed to operate in on-off, PID, or variable pulse modes. The Controller is shown in
Figure 1G, below. By following these instructions, the Controller can be installed into any Middleby
Marshall oven equipped with the following Controllers.
• P/N 28071-0012 (Fig. 1A) • P/N 28071-0028 (Fig. 1E)
Analog Temperature Controller without high-limit and Digital Temperature Controller with gray rubber face
cooldown functions, operating at 120V, on-off mode only. plate and buttons with symbols, operating at 120V, on-
• P/N 28071-0018 (Fig. 1A) off mode only.
Analog Temperature Controller with high-limit and • P/N 30871 (Fig. 1E)
cooldown functions, operating at 120V, on-off mode only. Digital Temperature Controller with gray rubber face
• P/N 34983 (Fig. 1B) plate and buttons with symbols, operating at 208-240V,
Analog Temperature Controller without high-limit and on-off mode only. Used on early PS360WB70 and some
cooldown functions, operating at 120V, on-off mode only. CE oven models.
Used on PS200VL models. As of 12/01, P/N 34983 is • P/N 32571 (Fig. 1E)
still available and should be used on these ovens if Digital Temperature Controller with gray rubber face
possible. plate and buttons with symbols, operating at 208-240V,
• P/N 28071-0027 (Fig. 1C) PID mode only. Used on early PS360EWB.
Digital Temperature Controller with blue plastic face- • P/N 36021 (Fig. 1F)
plate, operating at 120V, on-off mode only. Digital Temperature Controller with gray face plate (steel
• P/N 28071-0028 (Fig. 1D) trim on edges), operating at 120-240V, selectable on-
Digital Temperature Controller with gray rubber face- off or PID modes.
plate and buttons with text, operating at 120V, on-off • P/N 36056 (Fig. 1G)
mode only. Digital Temperature Controller with black plastic face
plate, operating at 120-240V, selectable on-off or PID
modes.
Figure 1

A B

C D E F G
This Kit CANNOT be installed in a PS536 oven equipped with the P/N 44783 (variable pulse electric) or
P/N 44823 (PID gas) controller shown below.

H
Page 2 of 10

34
 SECTION 3 - SERVICING COMPONENTS

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

WARNING
BEFORE PERFORMING ANY SERVICE WORK, THE ELECTRICAL POWER SUPPLY
AND THE GAS SUPPLY MUST BE TURNED OFF.

Before you Begin

1. This Temperature Controller requires a current-version thermocouple for proper operation. Check
that the thermocouple(s) installed in the oven match the current three-lead, flanged versions BE-
FORE you begin to install the Temperature Controller. See Figure 2.
If the oven is not equipped with current thermocouples, you should replace them BEFORE you install
the new Temperature Controller.
P/N 33984: Thermocouple kit for PS300-series, PS555 and PS570
P/N 33985: Thermocouple kit for PS200-series and PS536

Figure 2
flange Cable
(3 leads)

Current thermocouple

Cable
(2 leads)

Obsolete 2-lead
thermocouple
clip
Installation
1. Check the oven’s existing temperature controller, as shown on the previous page.
• IF THE EXISTING CONTROLLER IS P/N 36056 OR P/N 46837 (shown in Figure 1G), the new
controller can be installed directly into the existing sleeve as follows:
- Loosen the Phillips screw at the bottom center of the faceplate.
- Pull the old controller out of the sleeve.
- Skip ahead to the Jumper Setting section of these instructions on Page 6 to set up the new
controller. After the jumper is configured, the new controller can be installed directly into the
existing sleeve.
• IF THE EXISTING CONTROLLER IS OF ANY OTHER TYPE, the sleeve will have to be replaced
with the one included in this Kit. Continue on to Step 2 in this section.
2. Access the back of the existing temperature controller. Tag each wire that connects to the controller
with its terminal number. These numbers will be used later to wire the new controller.
3. Disconnect all wires from the terminals on the temperature controller. Be sure to retain any jumpers
that are removed.
4. Remove the controller and sleeve from the oven as follows:
• For analog controllers P/Ns 28071-0012 and 28071-0018 (Fig. 1A), remove the two bracket
screws on the back of the control. Then, remove the bracket. Pull the controller and sleeve out
through the front of the oven panel.
• For all other controllers, remove the two screws and brackets that hold the controller in place.
Then, pull the controller and sleeve out through the front of the panel.
Page 3 of 10

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SECTION 3 - SERVICING COMPONENTS

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

5. Check that the new controller is mounted into its sleeve. Then, slide the assembly into the opening in
the panel from the outside. Check that the controller is upright, with the display on top and the
keypad on the bottom.
6. Locate the rectangular holes on the top and bottom of the new controller’s sleeve. Attach the two kit-
supplied mounting brackets against the inside panel of the oven, and into the holes in the sleeve, as
shown in Figure 3. Check that the heads of the screws point to the rear of the controller.
7. Tighten the two screws evenly until the lip of the sleeve is seated tightly against the panel.
8. If there is a protective clear plastic strip on top of the display, remove it at this time.

Figure 3

Temperature controller is
pre-installed into sleeve
and is upright

Control
panel

Bracket clips and

screw heads point to
REAR of controller

Electrical Connections
1. Wire the new controller as follows:
• If you are replacing an Analog Temperature Controller, P/Ns 28071-0012 or 28071-0018 (see
Fig. 1A), refer to Figure 4A for a listing of the new terminal numbers.
• If you are replacing an Analog Temperature Controller P/N 34983 (Fig. 1B - PS200VL models
only), refer to Figure 4B for a listing of the new terminal numbers.
• If you are replacing any Digital Temperature Controller, simply reconnect ALL of the original
wires and jumpers to the same terminals, as all terminals are numbered the same.
EXCEPTION: Controller P/N 32571(Fig. 1E - used on early PS360EWB ovens only) uses Termi-
nals 4 & 5 for the mA output to the amplifier board. The current controller uses Terminals 15 & 16 for
these connections, as shown in Figure 5A.
Page 4 of 10

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 SECTION 3 - SERVICING COMPONENTS

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

Figure 4a Figure 4b
Analog temperature controller (P/Ns Analog temperature controller
28071-0012 and 28071-0018) terminals (P/N 34983) terminals

New temperature New temperature

controller terminals controller terminals

Not used. PS200VL

Not used on ovens have a sepa-
some gas and rate high limit module
Not used electric ovens Not used and do not include a
cooldown feature.

Not used Not used

Not used. These Not used. PS200VL

terminals provide PID ovens do not include a
output (gas ovens modulating gas system.
with modulating
valve) or variable
pulse output (electric ovens with
variable pulse system). Neither of
these systems were available with
ovens equipped with these
controllers.
Terminal for
28071-0012 and Terminal for Terminal for Description
28071-0018 34983 46837
1 TC+ 8 + TC
2 TC- 7 - TC
5 COM 5 Input to Temperature Control Relay
6 NO 4 Output to High Flame Solenoid or Heater Contactors
L2 L2 L2 Neutral
L1 L1 L1 Power
G G Ground
13 -- 9 Input to Cooldown Relay
14 -- 10 Output from Cooldown Relay
15 -- 11 Input to High Limit Relay
16 -- 12 Output from High Limit Relay
-- -- 15 PID or Variable Pulse Output
-- -- 16 PID or Variable Pulse Output

Figure 5a Figure 5b
Modulated Gas Output System Variable Pulse Output System
Modulating
Amplifier board valve
4-20mA
input Relay

20VDC pulsed output

0-24VDC
output

NOTE: Safety switches

NOTE: Controller P/N 32571 used Terminals 4 & 5 may be placed between
for the 4-20mA input to the amplifier board. 24VAC the temperature controller
These connections must be moved to Terminals input and the relay on some
15 & 16 on the new controller as shown. oven models.
Page 5 of 10

37
SECTION 3 - SERVICING COMPONENTS

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

Jumper Setting
Loosen the Phillips screw at the bottom center of the faceplate. Then, pull the controller out of its sleeve.
Next, access the jumper shown in Figure 6. This jumper affects the signal that is output from Terminals
15 and 16. The jumper MUST be set to the correct position for proper operation of the controller.

CAUTION
If the jumper is incorrectly set, the oven will be unable to properly maintain temperature. In addi-
tion, DAMAGE MAY OCCUR TO THE CONTROLLER AND OTHER OVEN COMPONENTS.
Always make sure that the jumper is correctly set BEFORE restoring power to the oven!

• For gas ovens equipped with the modulating gas system, the jumper must be set to the
“W1” position.
This instructs the controller to send a variable-current 4-20 mA signal from Terminals 15 and 16 to
the amplifier board. The board converts this to a 0-24VDC signal which is sent to the modulating
valve. The valve regulates the gas flow according to the need for heat to maintain the set point.
For gas ovens, you should always check inside the machinery compartment to see whether a modu-
lating valve is present in the unit before setting this jumper.
• For electric ovens equipped with the variable pulse system, the jumper must be set to the
“W2” position.
This instructs the controller to send a constant-current, pulsed 20VDC signal to the relay. Once per
second, the signal “pulses” on proportional to the need for heat to maintain the set point.
As of 1/02, only the PS536 Electric oven uses the variable pulse system. Other oven models equipped
with this system will be announced by Middleby as they become available.
• For all other ovens - gas or electric - that use the on-off system, the jumper may be set to
either position.
After the jumper has been properly set, replace the controller into its sleeve and tighten the screw.

Figure 6 Programming
1. Restore electrical power to the oven.
2. Refer to Figure 7. Set the following options,
according to the customer’s preferences:
• Set Point locked or unlocked
• Degrees Fahrenheit or Celsius
• Set Point or Actual Temperature display
3. Set the controller to PID or On-Off operating
mode. Choose the PID mode for BOTH gas
ovens with the modulating system AND for elec-
tric ovens with the variable pulse system.
4. Adjust the Set Point according to the
customer’s specifications.
5. If the PID operating mode was chosen, per-
form an Auto-Tune calibration as per the in-
structions in Figure 7.
6. Check that the customer is familiar with the
operation of the controller. The last page of
Jumper is set to the “W1” Jumper is set to the “W2”
these instructions includes an operating guide
position for gas ovens with position for electric ovens for the controller. Remove this page and leave
modulating gas system with variable pulse system it with the customer for future reference.
Page 6 of 10

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 SECTION 3 - SERVICING COMPONENTS

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

Temperature Controller Service Instructions

Figure 7

Page 7 of 10

39
SECTION 3 - SERVICING COMPONENTS

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

Diagnostic Error Messages

The controller runs background tests during normal operation. If any problems occur during the tests, an
error message flashes in the display. A listing of these diagnostic error messages is shown below.

1. Turn the Blower Switch (HEAT Switch for PS536 ovens with the two-
switch configuration) OFF for 2 minutes.
2. Turn the Blower Switch (or HEAT Switch, as per Step 1) ON.
Flashes on the display (alter- 3. If necessary, repeat Steps 1 and 2 up to two additional times.
nating with the temperature) 4. If the problem does not clear after 3 attempts, replace the controller.
indicating that the internal di-
agnostic test has failed.

1. Turn the Blower Switch (HEAT Switch for PS536 ovens with the two-
switch configuration) OFF for 2 minutes.
2. Turn the Blower Switch (or HEAT Switch, as per Step 1) ON.
The oven temperature has 3. If the problem does not clear, contact the Middleby Technical Ser-
not reached 200°F/93°C vice Department for assistance.
within 15 minutes of startup.
On gas ovens, this is usually
a result of the burner not light-
ing.

1. Check that the thermocouple leads are properly connected to Ter-

minals 7 & 8 of the temperature controller.
2. Check the continuity of the thermocouple at room temperature. You
Caused by an open in the should measure 9-20 Ohms of resistance.
thermocouple circuit. 3. If the reading was outside the correct range, the thermocouple has
an open. Remove and replace the thermocouple.
If the reading was inside the correct range, contact the Middleby
Technical Service Department for assistance.

1. Check the polarity of the thermocouple leads. The red wire (-) should
be attached to Terminal 7 on the temperature controller. The white
wire (+) should be attached to Terminal 8.
2. If the polarity connections are incorrect, connect the thermocouple
Polarity of the thermocouple
properly.
leads is reversed.
If the polarity connections are correct, replace the thermocouple.

Page 8 of 10

40
 SECTION 3 - SERVICING COMPONENTS

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

Digital Temperature Controller

P/N 46837
Operating Instructions

Display "HEAT ON" Light

Shows the Set Point or Lights when the
the Actual Tempera- burner or heating ele-
ture in degrees Fahr- ments, as appropriate
enheit (F) or Celsius for the oven model,
(C). are in operation.
"SP LOCK" Light
Lights when the set
point is locked out
from changes. This "SET PT" (setpoint)
setting can only be Light
changed by service Lights when the set
personnel. point is shown in the
display.

"ACTUAL TEMP"
OVERTEMP Light Light
Lights when the oven Lights when the
temperature is greater Actual Tempera-
than 650°F (343°C). ture is shown in
the display.

Temperature Key Service Key

Press this key once to For use by ser-
view the Actual Tem- vice personnel
perature in the Dis- only.
play.

Unlock Key Set Point Key

Press this key together Press this key together
with the Set Point Key with the Unlock Key to
to allow the Set Point Up Arrow and Down Arrow allow the Set Point to
to be changed. Changes Keys be changed.
can only be made for Press these keys to adjust Changes can only be
60 seconds. the Set Point up or down. If made for 60 seconds.
the Set Point will not
change, refer to Set Point
Key and Unlock Key.

41
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

42
 SECTION 3 - SERVICING COMPONENTS

Appendix - Service Bulletin MM-136 - Electrical Noise

Filter Capacitor Assembly on Temperature Controllers, 9/93

43
SECTION 3 - SERVICING COMPONENTS

Appendix - Service Bulletin MM-136 - Electrical Noise

Filter Capacitor Assembly on Temperature Controllers, 9/93

44
 SECTION 3 - SERVICING COMPONENTS
III. HIGH LIMIT CONTROL MODULE C. Operation and Troubleshooting
On most PS200-series and PS300-series gas ovens, the Refer to the wiring diagrams at the back of this manual for
temperature controller monitors the high limit. All other high limit wiring connections.
oven models use a High Limit Control Module that is inde- The Watlow high limit control module generally uses a dedi-
pendent of the temperature controller. cated high limit thermocouple. Some older ovens use a
Middleby ovens have used several different types of high dual-function, four-lead thermocouple that sends a signal
limit control modules. See Figure 23. to both the temperature controller and the high limit control
• The United Electric Type 54 control was used for high module. Refer to Thermocouples on Page 54 for details.
limit functions only. Ovens equipped with this control If the temperature sensed by the high limit thermocouple
did not have a cooldown feature. The control was used exceeds 650°F/343°C, the high limit control module will
on early PS310 and PS360 electric ovens. shut down the oven and illuminate the green reset button.
• The United Electric Type 55 control included both high The module will need to be reset (by pressing the reset
limit and cooldown functions, and was used on PS310 button) before the oven can be operated. The reset button
and PS360 electric ovens. is located inside the machinery compartment to ensure that
it is reset by an authorized service agent. The agent should
• The Watlow high limit control module is the only ver- determine and correct the cause of the high limit condition
sion still in use by Middleby. The module includes before returning the oven to service.
high limit functions only. The cooldown function is con-
trolled by the oven’s temperature controller, except on An open high limit thermocouple will trigger the high limit
PS200VL-series ovens, which do not include a control module to shut down the burner. The high limit
cooldown feature. control will need to be reset after the open is corrected (as
per the procedure described above) before the oven can
The Watlow high limit control module is used on PS200-
return to operation.
series, PS360-series, and PS555/570-series ovens.
Service information in this Manual is limited to the current Figure 23 - High limit control modules
Watlow high limit control module. The United Electric units
are no longer available. Service Kit P/N 39733 can be used (Shown in PS360-series oven)
to upgrade either of the two previous controllers to the United Electric Type 54
Watlow version. high limit control module
A. Part Number Reference - High Limit Control Mod-
ules
P/N Description
28071-0002 United Electric Type 54 high limit control module
No longer available - upgrade to current model
34982 using Service Kit 39733
28071-0014 United Electric Type 55 high limit/cooldown con-
trol module
No longer available - upgrade to current model
34982 using Service Kit 39733
34982 Watlow high limit control module, 115V United Electric Type 55
For use on ovens with 120V control circuits high limit/cooldown
control module
33983 Watlow high limit control module, 240V
For use on ovens with 208-240V control cir-
cuits
30693 Illuminated reset button (green) for Watlow con-
trol (all voltages)
39733 High Limit Conversion Kit for PS300, PS310,
PS350, and PS360 ovens
Replaces P/Ns 28071-0002 or 28071-0014 with
P/N 34982
B. Location Watlow high limit
control module
On ovens that include the separate high limit control mod-
ule, it is located: Reset button
• PS200-series - Inside the machinery compartment.
• PS360-series - Inside the control compartment.
• Early PS555 ovens - Inside the left blower motor com-
partment.
• Current PS555 and all PS570 ovens - Inside the
machinery compartment.
45
SECTION 3 - SERVICING COMPONENTS

D. Appendices Appendix - Instructions for Service Kit 39733 -

High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99

Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • USA • (847) 741-3300 • FAX (847) 741-4406

Instructions for Service Kit 39733

High Limit Conversion Kit for PS300, 310, 350, & 360 Ovens
KIT COMPONENTS - Check that the kit includes ALL of these parts BEFORE you begin!
Qty. P/N Description Qty. P/N Description
1 39732 Instructions 2 ft./610mm 27152-0050 Wire, #18 AWG, brown
1 34982 Watlow high limit control module 2 ft./610mm 27152-0053 Wire, #18 AWG, white
1 30693 Reset switch w/ lighted pushbutton 2 ft./610mm 27152-0054 Wire, #18 AWG, purple
1 35634 Mounting bracket, reset switch 8 1455A8750 Wire connector, 1/4”/6.4mm
1 35691 Wire set, reset switch (includes 4 1 3002693 Wire tie, nylon
wires and 3 1/4”/25mm connectors) 2 2000076 Screw, 6-32 X 1-5/8”
1 33812-1 Thermocouple, type J, 6”/152.4mm 2 1421B8803 Screw, 6-32 X 1/4”
1 39690 Mounting sleeve, thermocouple 4 2001327 Nut, 6-32

TOOLS REQUIRED
Figure 1
• Drill with 3/16” drill bit
• Middleby Marshall Thermocouple Signal Source United Electric Type 54
Generator (P/N 27170-0192) High Limit Control
• Wire cutters/strippers

A. OVERVIEW
This Service Kit is used to replace two different types of
United Electric high limit/cooldown controllers with a
Watlow high limit controller for PS300, 310, 350, and
360 Ovens. See Figure 1.
• The early (Type 54) United Electric control was ONLY
equipped with a high limit circuit. Ovens equipped
with this control did NOT have a cooldown circuit. United Electric Type 55
This control was used on the following models: High Limit/Cooldown
- PS300/350 Gas (early) Control
- PS300/310/350/360 Electric (early - all voltages)
For these ovens, the kit directly replaces the Type
54 high limit control with the Watlow high limit con-
trol.
• The later (Type 55) United Electric control was
equipped with BOTH high limit and cooldown circuits,
and was used on the following models:
- PS300/310/350/360 Electric (late), 208/240V and
Lighted Reset
480V UL versions ONLY
Switch
For these ovens, the kit replaces the Type 55 con-
Watlow High
trol with the Watlow high limit control, and uses the
Limit Control
oven’s temperature controller to provide the
cooldown circuit.

P/N 39732
Page 1 of 8 Rev. B • V1 • 5/99

46
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 39733 -

High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99

B. INSTALLATION
WARNING
BEFORE PERFORMING ANY SERVICE WORK, THE GAS SUPPLY (IF SO EQUIPPED) AND
THE ELECTRICAL SUPPLY TO THE OVEN MUST BE TURNED OFF.
1. Open the machinery compartment and control compartment access panels.
2. Locate the high limit thermo bulb/capillary assembly. Its location is shown in Figure 2. Loosen the set
screw that holds the assembly in place. Remove the thermo bulb/capillary assembly from the mount-
ing tube.
3. Disconnect the wires (2 for the Type 54 control, 4 for the Type 55 control) from the terminals of the
United Electric control. Bundle the loose wires together, and allow them to hang loose for later
reconnection.
4. Remove the mounting screws that hold the United Electric high limit control in place. Then, remove
and discard the high limit control and its mounting screws.
5. Position the new high limit control in place on the left wall of the control compartment, as shown in
Figure 3. When positioning the control:
• Ensure that the control is positioned AT LEAST 1” (25mm) back into the compartment to allow the
compartment door to close.
• Ensure that additional space is left underneath the control for the reset switch.
NOTE: Instead of holding the high limit control in place, you may use the dimensions provided in
Figure 4 to determine the location of the control and its mounting holes.
6. Mark the locations of the two mounting holes for the high limit control. Then, drill the holes using a
3/16” drill bit.
7. Secure the high limit control in place using the kit-supplied 6-32 x 1-5/8” screws and 6-32 nuts.
8. Position the bracket for the reset switch on the left wall of the control compartment, as shown in Figure
3. Note that the face of the bracket with the large, circular switch-mounting hole should face YOU.
Also, the bracket should be positioned AT LEAST 3” (75mm) back into the compartment to allow the
door to close.
9. While holding the bracket in place, mark the locations of the two mounting holes. Then, remove the
bracket and drill the holes using a 3/16” drill bit.
10. Secure the bracket to the panel using the kit-supplied 6-32 x 1/4” screws and 6-32 nuts. DO NOT
INSTALL THE RESET SWITCH INTO THE BRACKET AT THIS TIME.
11. Insert the kit-supplied thermocouple into its mounting sleeve. Position the sleeve so that the mounting
hole is at the base of the thermocouple, not the tip. See Figure 5.
12. Insert the thermocouple and mounting sleeve into the original mounting tube. The set screw opening
in the sleeve should align with the set screw hole on the side of the mounting tube.
Push the thermocouple into the opening until its base seats firmly on the mount. See Figure 6.
13. Insert the thermocouple’s set screw into the hole on the side of the mounting tube. Tighten the set
screw to hold the thermocouple and sleeve in place.
14. Thread the thermocouple’s shielded cable into the electrical compartment. Coil the free end of the
cable and fasten it with the kit-supplied nylon wire tie. Be sure to leave enough free cable to reach the
new high limit control.
Page 2 of 8

47
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 39733 -

High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99

Figure 2
High limit thermocouple location -
lower oven

High limit thermocouple location -

upper oven

Figure 3 Figure 4
NOT TO SCALE

Figure 5 Figure 6

Thermocouple
Base

Sleeve

Hole in sleeve is
next to base of
thermocouple

Page 3 of 8

48
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 39733 -

High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99

C. WIRING
For the various wiring connections listed below, cut the kit-supplied #18 AWG wires to length. Refer to
Figures 7 and 8 (on pages 6 and 7) for diagrams of the wiring connections.
Lighted Reset Switch Wiring and Installation
14. Using the kit-supplied 1/4” wire connectors, connect the following kit-supplied wires:
- Red wires ................. connect one wire to each “RESET” terminal on the high limit control
- Black wire ................. connect to terminal “NC” on the high limit control
- White wire ................. connect to terminal “L2” on the oven’s temperature controller
15. Slip the free ends of these four wires through the circular hole in the reset switch mounting bracket, so
that they hang down in front of the control compartment.
16. Use the kit-supplied 1/4” wire connectors to connect these four wires to the terminals on the lighted
reset switch.
- Terminals 1 and 3 ..... Red wires (these connections are interchangeable)
- Terminal 2 ................ Black wire
- Terminal 4 ................ White wire (kit-supplied)
17. Push the lighted reset switch through the mounting hole in the center of the bracket until it snaps into
place. Be sure to avoid pinching the wires against the sides of the mounting hole.
Cooldown circuit wiring
NOTE: Perform steps 18 and 19 ONLY if you are replacing a UE Type 55 controller. If you are
replacing a UE Type 54 controller (which has no cooldown circuit), skip ahead to Step 20.
18. Attach the oven’s existing cooldown wiring to the following terminals on the oven’s Temperature Con-
troller, as shown in Figures 7 and 8.
For Ovens with a Digital Temperature Controller:
a. Terminal 9 ................ Black wire (from blower switch)
b. Terminal 10 .............. Brown wire (from blower switch)
For Ovens with an Analog Temperature Controller:
a. Terminal 13 .............. Black wire (from blower switch)
b. Terminal 14 .............. Brown wire (from blower switch)
19. Attach a brown kit-supplied wire between the following terminals on the Temperature Controller:
Digital Controller ............. Terminals 10 and “L1”
Analog Controller............ Terminals 13 and “L1”
High Limit Control wiring
20. Using the kit-supplied 1/4” wire connectors, wire the high limit control terminals as follows:
a. Terminal “NO” ........... Purple wire (originally to UE control)
c. Terminal “TC +” ........ White wire (to thermocouple) - DO NOT CUT THIS WIRE TO LENGTH.
d. Terminal “TC -” ......... Red wire (to thermocouple) - DO NOT CUT THIS WIRE TO LENGTH.
f. Terminal “L2” ............ White wire (kit-supplied; to neutral on the oven’s terminal block)
h. Terminal “COM” ........ Orange wire (originally to UE control)
21. Using a 1/4” wire connector, attach a brown kit-supplied wire to the “L1” terminal on the high limit
control. Attach the free end of the wire to the “L1” terminal on the temperature controller.

Page 4 of 8

49
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 39733 -

High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99

D. TESTING THE INSTALLATION

22. Remove the thermocouple wires from the “TC +” and “TC -” terminals on the high limit control.
23. Attach a Middleby Marshall Thermocouple Source (P/N 27170-0263) to the “TC +” and “TC -” termi-
nals on the high limit control, in place of the thermocouple wires. Note that it may be necessary to
attach a pair of terminal connectors to the leads of the Thermocouple Source to allow them to connect
to the high limit control’s terminals.
24. Restore the gas supply (if so equipped) and the electrical supply to the oven. Because the control
compartment door is still open, pull the door safety switch out into the “service” position.
25. Test the operation of the high limit control as follows:
a. Set the Thermocouple Source to a normal operating temperature, between 200°-600°F (93°-315°C).
b. Turn the oven on, and allow it to heat to 600°F (315°C).
c. After the oven has reached the setpoint temperature, set the Thermocouple Source to 700°F (371°C).
The high limit control is set to open at any temperature in excess of 650°F (343°C). This will shut
down the oven’s heat circuit and illuminate the Reset Switch lamp.
26. Set the Thermocouple Source to a temperature setting below 600°F (316°C), and depress the Reset
Switch. This should turn off the Reset Switch lamp and restore heat circuit operation.
27. Turn the oven off.
28. If you replaced a UE type 55 controller (with a cooldown circuit), you must set the Thermocouple
Source to a temperature setting below 200°F (93°C). Then, wait for the blowers to turn off.
29. Press the door safety switch in to reset it to normal.
30. Remove the Thermocouple Source from the oven.
31. Reattach the thermocouple wires to the high limit control’s terminals as follows:
White wire ................ “TC +”
Red wire ................... “TC -”
32. Close the machinery compartment and control compartment access panels, and fasten them in place.
The oven is now ready for normal operation.

Page 5 of 8

50
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 39733 -

High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99
Figure 7 - United Electric Model 55 replacement: ovens with a cooldown feature

KEY

Page 6 of 8

51
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 39733 -

High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99
Figure 8 - United Electric Model 54 replacement: ovens without a cooldown feature

KEY

Page 7 of 8

52
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 39733 -

High Limit Conversion Kit for PS300, 310, 350 & 360 Ovens, 5/99

A MIDDLEBY COMPANY

Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • USA • (847) 741-3300 • FAX (847) 741-4406
Middleby Corporation Service Hotline 1-800-238-8444
www.middleby.com
Page 8 of 8

53
SECTION 3 - SERVICING COMPONENTS
IV. THERMOCOUPLES Figure 24 - Thermocouples
All temperature controller and high limit functions are based Cable
on input from thermocouples. When two wires composed flange (3 leads)
of dissimilar metals are joined together and one of the ends
is heated, a continuous current flow is generated. Middleby
ovens use a Type J (iron constant) thermocouple. The iron Current 3-lead
wire increases the number of dissimilar metal junctions in thermocouple
the circuit. Cable
(2 or 4 leads)
Middleby has used several types of thermocouples. All
can be replaced with the current version. Refer to Figure
24 for illustrations. Obsolete 2-lead
• A two-lead thermocouple with a small retaining clip. or 4-lead
thermocouple clip
Used for EITHER temperature-sensing OR high-limit
functions. This type is no longer available.
• A four-lead thermocouple with a small retaining clip.
This is a dual-function unit that sends its signal to the A. Part Number Reference - Thermocouples
temperature controller and to a separate high limit con- Part numbers are provided ONLY for the current, 3-lead ther-
trol module. This type is no longer available. mocouple kits. These thermocouples include instructions
• A three-lead thermocouple with a separate ground lead, for replacing all previous thermocouple designs, in all oven
a shielded cable and a large mounting flange. This is models.
the only type of thermocouple available from Middleby P/N Description
at this time. If it is used to replace a four-lead dual- 33984 Kit, thermocouple, PS360-series or PS555/570
function thermocouple, two complete and separate ther- series
mocouples will have to be installed. 33985 Kit, thermocouple, PS200-series or PS536

B. Thermocouple Functions 2. High limit thermocouple

1. Temperature-sensing thermocouple(s) Middleby uses the term “high limit thermocouple” in
All thermocouples monitor oven temperature. However, reference to the thermocouple that sends its signal
Middleby uses the term “temperature-sensing thermo- solely to the separate high limit control module.
couple” in reference to thermocouples that send their If the oven does not have a separate high limit control
signal to the temperature controller instead of to a sepa- module, there is no high limit thermocouple. On these
rate high limit control module. ovens, the temperature-sensing thermocouple(s) con-
On ovens that do NOT include a separate high-limit trol high limit activation.
control module (this includes most PS200-series and C. Troubleshooting
PS360-series gas ovens), this thermocouple signal is
used to monitor the oven temperature for regulating the 1. Open thermocouple
gas flow/heater activation, AND to activate the high limit An open in a thermocouple will cause the temperature
warning in case of an overtemp condition. controller to read the maximum temperature (usually
Middleby ovens use from one to three temperature-sens- 909°F/487°C). This causes the following:
ing thermocouples, depending on the oven model. • On ovens without a separate high limit control mod-
Temperature-sensing thermocouples are used on all ule, an open thermocouple triggers the high limit
oven models and are connected to Terminals 7 and 8 alarm. This shuts down the burner. After the open
on the temperature controller. Based on the signal from has been corrected, the high limit will need to be
this thermocouple, the temperature controller: reset to allow the oven to resume operation.
• Calls for heat from the burner/heating elements to • On ovens with a separate high limit control mod-
maintain the set point (output from Terminals 4 & 5 ule, an open temperature-sensing thermocouple
for on-off electric and gas ovens; output from Ter- causes the temperature controller to stop calling
minals 15 & 16 for variable pulse electric and modu- for heat. This shuts down the burner.
lating gas ovens). • On ovens with a separate high limit control mod-
• Controls the cooldown feature if the HEAT switch ule, an open high limit thermocouple will trigger the
is turned off while the oven is above the cooldown high limit control module to shut down the burner.
temperature (output from Terminals 9 & 10). Note that the high limit control will need to be reset
after the open is corrected before the oven can re-
• On ovens without a separate high limit control mod-
turn to operation.
ule (most PS200-series and PS360-series gas and
electric ovens), the oven temperature sensed by
this thermocouple is also used to activate the high
limit warning (output from Terminals 11 & 12).
54
 SECTION 3 - SERVICING COMPONENTS
2. Checking the thermocouple with a DC millivolt meter mocouple into an ice bath for several minutes. At 72°F/
It is possible to check that a thermocouple is reading 22°C the reading should be 1.134mVDC.
accurately by using a multimeter set to read DC milli- You can use the chart below by checking the tempera-
volts. At 32°F/0°C the thermocouple should read ture at the thermocouple’s junction terminals. This is
0 mVDC. This can be checked by inserting the ther- called the Junction Temperature.

Figure 24 - Thermocouple millivolt readings at various operating and junction temperatures

55
SECTION 3 - SERVICING COMPONENTS

D. Appendices Appendix - Instructions for Service Kits 33984 and 33985 -

Oven Thermocouple Kit, 11/01

Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • USA • (847) 741-3300 • FAX (847) 741-4406

Instructions for Service Kits P/Ns 33984 and 33985

Oven Thermocouple Kit
This Service Kit provides the parts and instructions necessary to replace one temperature-sensing or high limit thermo-
couple in any of the following Middleby Marshall oven models:
• PS200 Series uses Kit P/N 33985 • PS536 uses Kit P/N 33985 • PS570 uses Kit P/N 33984
• PS360 Series uses Kit P/N 33984 • PS555 uses Kit P/N 33984
These instructions include replacement procedures for ovens built with the current flanged thermocouple, AND for ovens
built with the obsolete thermocouple without a flange (P/N 28071-0001).

KIT CONTENTS - KIT P/N 33984 KIT CONTENTS - KIT P/N 33985
P/N Qty. Description P/N Qty. Description
33812-1 1 Thermocouple, type J, 6” L 33812-2 1 Thermocouple, type J, 13-3/8” L
B301A8861 2 Screw, hex wshr hd #6 x 3/8” B301A8861 1 Screw, hex wshr hd #6 x 3/8”
21292-0001 3 Screw, hex wshr hd #10-16 x 3/4” 34701 1 Instructions
27276-0001 1 Cable clamp, nylon
41687 1 Attachment plate, PS360 rear thermocouple
34701 1 Instructions

IMPORTANT - READ THIS BEFORE YOU BEGIN!

The thermocouple in your Kit has three leads:
• The red and white leads connect directly to the thermocouple terminals on the oven’s temperature controller (or high
limit control module, as appropriate), or to a local terminal block that in turn is connected to one of these units.
• The uninsulated lead is a ground wire for the thermocouple’s protective sheath. The ground connection helps to drain
any radio-frequency disturbances from the thermocouple before the signal enters the temperature controller or high
limit control module. For a temperature-sensing thermocouple, the ground lead MUST be connected to the ground
terminal on the temperature controller. For a high limit thermocouple, the ground lead should be connected to a
chassis ground or to the mounting screw for the high limit control module.
Some early thermocouples may have either two or four leads:
• The two-lead thermocouple is simply an earlier version of the current model, without the ground lead. When replacing
a two-lead thermocouple, it will be necessary to connect the new ground lead.
• The four-lead thermocouple is actually a dual-function unit which sends its signal to both the temperature controller
and the high limit control module. Current ovens use separate thermocouples for these functions. When replacing a
four-lead thermocouple, it will be necessary to use a SECOND KIT to install the high limit thermocouple. In addition,
any oven equipped with these early thermocouples should have all of its thermocouples updated at the same time. For
a PS570 or PS570S oven, this will require THREE THERMOCOUPLE KITS - two for the existing thermocouples, and
one for the new, separate high limit.

Oven Model Page Oven Model Page

PS200 Series - before 2/96, serial numbers before ASH-0001 ........... 2 PS555 Gas - rear wall thermocouples with screw terminal
PS200 Series - 2/96 or later, serial numbers after ASH-0001 ............. 2 connections (no terminal blocks) ......................................................... 8
PS360 Series rear wall thermocouples - before 2/96, serial PS555 Electric and PS555E ............................................................... 9
numbers before ASH-0001 ................................................................. 3 PS570 (X01-X05 name plate ID numbers) and PS570S
PS360 Series rear wall thermocouples - 2/96 or later, serial (early) with side-mounted thermocouples inside or outside
numbers after ASH-0001 .................................................................... 3 the blower motor compartments ........................................................ 10
PS360 Series front-mounted thermocouples inside the PS570S (late) - rear wall thermocouples with left-side AND
machinery compartment ...................................................................... 4 right-side terminal block connections ................................................. 12
PS536 ................................................................................................ 5 PS555G and PS570G - rear wall thermocouples with
left-side terminal block connections .................................................... 14

WARNING
BEFORE PERFORMING ANY SERVICE WORK, THE ELECTRICAL POWER SUPPLY AND THE GAS SUPPLY MUST BE TURNED OFF.
1 P/N 34701 • Rev. C • V1 • 11/01

56
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kits 33984 and 33985 -

Oven Thermocouple Kit, 11/01
PS200 Series - before 2/96, serial numbers Figure 1
Thermocouple Installation - PS200 Series
before ASH-0001
Mounting
Thermocouples on these ovens are located inside the ma- Thermocouple Mounting tube
chinery compartment. They are secured in place by a set tube screw
screw in the mounting tube, inside the plenum chamber.
This Kit eliminates the set screw. The new thermocouple
is held in place by the head of the screw that is already Thermocouple
Set screw Oven flange
used to attach the mounting tube. (not used with new wall
Tube
thermocouple) flange

NOTE FOR HIGH LIMIT THERMOCOUPLES:

CE ovens and PS200VL models have two thermocouples,
one mounted above the other. In these ovens, the upper
thermocouple senses the oven temperature and is con-
nected to the temperature controller. The lower thermo-
couple is connected to the high limit control module. Ei-
ther thermocouple can be replaced using this Kit.

1. Remove the lower end plug from the control end of the
oven. Then, remove 1 or 2 lower air fingers as neces-
sary to access the thermocouple mounting tube.
2. Refer to Figure 1. REMOVE AND DISCARD the set
screw and pull the thermocouple out of the mounting CORRECT INCORRECT
tube. Disconnect the thermocouple wiring from the tem- Thermocouple flange sits firmly on Thermocouple flange sits on top of
perature controller or high limit module, as appropriate. mounting tube flange; tube screw head, leaving a gap as
mounting screw holds thermo- shown.
couple in place.
3. Remove AND RETAIN the #10-16 screw that fastens
the flange of the thermocouple mounting tube to the
plenum wall. Leave the mounting tube in place. Figure 2
Thermocouple Wiring - PS200 Series
4. Install the new thermocouple so that its flange fits firmly
against the mounting tube flange. White

5. Replace the #10-16 screw that you removed in Step 3. Red

Check that the head of the screw holds the thermo- Digital
couple flange securely in place, as shown in Figure 1. Temperature
Controller
6. Route the thermocouple leads away from the ignition
Shielded
cable. Connect the leads as shown in Figure 2. ground lead

PS200 Series - 2/96 or later, serial numbers

after ASH-0001 Shielded
White Red ground lead
Thermocouples on these ovens are located in the same
position as the earlier PS200 models described above.
However, these ovens feature a flanged thermocouple iden- Analog
tical to the new thermocouple provided in this Kit. Temperature
Controller
The thermocouple SHOULD be held in place by the screw
that attaches the thermocouple mounting tube, as per the
replacement procedure above. For these ovens, simply
disconnect the thermocouple wiring from the temperature
controller and follow Steps 3-6 of the procedure shown above
Red White
to remove and replace the thermocouple.
On some of these ovens, the thermocouple flange rests Shielded
ground lead
ON TOP of the retaining screw for the mounting tube, as High Limit
shown in the “INCORRECT” inset of Figure 1. These ther- Control
mocouples are held in place by the set screw on the mount- Module
ing tube, inside the plenum chamber. For these ovens, you
should remove and replace the thermocouple by following
Steps 1-6 of the preceding section.
2

57
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kits 33984 and 33985 -

Oven Thermocouple Kit, 11/01
PS360 Series rear wall thermocouples - Figure 3
Thermocouple Installation - PS360 Series
before 2/96, serial numbers before ASH-0001
Clamp (remove
Thermocouples on these ovens are located on the rear wall and discard if
of the baking chamber. They are secured in place by a present)
Mounting
clamp on the outside of the oven. tube
Thermocouple (welded to
This Kit eliminates the clamp. The flange of the new ther- plenum)
mocouple is held to the back wall of the oven by a retaining
plate, as shown in Figure 3.
1. Loosen the retaining clamp and pull the thermocouple
Thermocouple
straight out. Disconnect the thermocouple leads. Care- Plenum flange
fully thread the wiring out of the oven and discard the wall
thermocouple. Oven
wall
2. Remove and discard the cable clamp.
New
3. Slide the new thermocouple into the mounting tube until thermocouple Retaining
plate
the flange is seated firmly on the back wall of the oven.
4. Install the kit-supplied retaining plate (P/N 41687) as
shown in Figure 3.
5. Fasten the attachment plate to the back wall of the
oven using the two kit-supplied #10-16 x 3/4” self-tap-
#10-16 x 3/4”
ping screws. Ensure that the thermocouple flange is mounting
securely trapped between the plate and the rear wall of screws (2)
the oven.
6. Route the wiring through the grommet hole and into the
machinery compartment. Check that the leads are clear
Figure 4
of all components, PARTICULARLY THE BLOWER Thermocouple Wiring - PS360 Series
MOTOR, by using the existing wiring bundles.
Digital Temperature Controller
7. Connect the leads as shown in Figure 4.
8. Attach the kit-supplied nylon clamp and #10-16 x 3/4” White
screw to the rear of the oven. The clamp should be
Red
positioned to support the thermocouple leads away from
the flue pipes and vent openings.

PS360 Series rear-wall thermocouples - 2/96

or later, serial numbers after ASH-0001
Thermocouples on these ovens are mounted directly to the
back wall of the oven using a single retaining screw. It
Shielded
should be possible to simply replace the existing thermo- ground lead
couple using the original mounting hardware.
To replace the thermocouple: Analog Temperature Controller
1. Remove AND RETAIN the screw that holds the thermo- Shielded
couple in place on the rear wall. White Red ground lead

2. Disconnect the thermocouple leads. Carefully thread

the wiring out of the oven and discard the thermocouple.
3. Slide the new thermocouple into the mounting tube until
the flange is seated firmly on the back wall of the oven.
4. Fasten the thermocouple to the back wall of the oven
using the original mounting screw. Then, perform Steps
6-8 of the preceding section to wire the thermocouple.

58
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kits 33984 and 33985 -

Oven Thermocouple Kit, 11/01
PS360 Series front-mounted thermocouple Figure 5
Thermocouple Installation - PS360 Series
inside the machinery compartment Machinery Compartment
These thermocouples are mounted in a tube that extends
diagonally up and into the plenum chamber. They are se-
cured in place by a set screw located on the mounting
tube, and by a bead of high-temperature silicone around Thermocouple
the end of the shaft. Set
screw
The new thermocouple will be held in place in the same High-temperature
silicone wraps around
manner, except that the silicone should be applied so that thermocouple flange
it wraps around the edges of the thermocouple’s mounting and onto mounting
tube
flange.

NOTE FOR HIGH LIMIT THERMOCOUPLES: Plenum

PS310/360 electric ovens have two thermocouples inside wall
the machinery compartment. One thermocouple is con-
nected to the temperature controller, while the other is Mounting
connected to the high limit control module. tube

The thermocouple supplied in this Kit is incompatible with

the early United Electric Type 54 and Type 55 high limit
control modules used on these ovens. If the oven is
equipped with one of these control modules, it will be
necessary to upgrade the control unit to the current Figure 6
Watlow model (shown in Figure 6) before the thermo- Thermocouple Wiring - PS360 Series
couple can be replaced. Service Kit 39733 includes all
parts and instructions needed for the conversion. Refer White
to Service Bulletin MM-168 (5/7/99) for details. Red
Digital
1. Remove the silicone seal around the end of the thermo-
Temperature
couple. Loosen the set screw.
Controller
2. Pull the thermocouple out of its mounting tube. Care- Shielded
ground lead
fully thread the wiring out of the oven and discard the
thermocouple.
Shielded
3. Check that the silicone has been removed completely White Red ground lead
from the end of the mounting tube. Any remaining sili-
cone can interfere with the correct placement of the
new thermocouple.
Analog
4. Insert the new thermocouple until its flange is seated Temperature
on the end of the mounting tube. See Figure 5. Controller
5. Tighten the set screw until the thermocouple is secure
inside the tube. AVOID OVERTIGHTENING THE SET
SCREW TO PREVENT DAMAGE TO THE THERMO-
COUPLE.
Red White
6. Use high-temperature silicone to seal the flange to the
Shielded
mounting tube, as shown in Figure 5. Check that all ground lead
holes and spaces are filled by the silicone. This not High Limit
only helps to hold the thermocouple in place, but pre- Control
vents heat from entering the machinery compartment. Module

7. Route the wiring for the new thermocouple through the

hole in the side of the electrical control box by using
the existing wiring bundle. Check that the leads are
clear of the ignition cable and all components.
8. Connect the leads as shown in Figure 6.

59
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kits 33984 and 33985 -

Oven Thermocouple Kit, 11/01
PS536 Figure 7
Thermocouple Installation - PS536
Thermocouples on these ovens are located inside the ma-
chinery compartment. They are secured in place by a sheet
metal screw that traps the thermocouple flange against the Sheet
metal
wall of the compartment. See Figure 7. screw

NOTE FOR HIGH LIMIT THERMOCOUPLES: Thermocouple Thermocouple

PS536 ovens have two thermocouples, one mounted flange

above the other. The upper thermocouple senses the

oven temperature and is connected to the temperature
controller. The lower thermocouple is connected to the
high limit control module. Either thermocouple can be Plenum
Machinery
compartment
replaced using this Kit. wall wall

1. Loosen the sheet metal screw that holds the thermo-

Temperature-
couple flange to the wall of the machinery compart- sensing
ment. thermocouple

2. Pull the thermocouple out of the machinery compart-

ment. Disconnect the thermocouple leads.
3. Install the new thermocouple so that its flange fits firmly
against the wall of the machinery compartment. Tighten
High limit
the sheet metal screw so that its head holds the ther- thermocouple
mocouple flange securely in place.
Screw head holds thermocouple
NOTE: PS536 ovens do not use a thermocouple mount- flange in place
ing tube, so it is CRITICAL that the thermocouple flange
is securely fastened to the wall of the machinery com-
partment.
Figure 8
4. Route the thermocouple leads away from the ignition Thermocouple Wiring - PS536
cable. Connect the leads as shown in Figure 8.
Digital Temperature Controller

White

Red

Shielded
ground lead

High Limit Control Module

Red White

Shielded
ground lead

60
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kits 33984 and 33985 -

Oven Thermocouple Kit, 11/01
PS555 Gas - thermocouples with screw ter- 3. Disconnect the thermocouple leads. Refer to Figure 9.
minal connections (no terminal blocks) • High limit thermocouples are wired directly to the
high limit control module. The thermocouple’s
Thermocouples on these ovens are located on the rear wall. ground wire is connected to the mounting screw
They are secured in place by two screws that are inserted for the high limit control module.
through the holes in the thermocouple flange. These ovens
are equipped with a three-lead, flanged thermocouple iden- • The red and white leads from ALL temperature-sens-
tical to the one in this Kit. ing thermocouples are joined at capped screw ter-
minals, located inside the left blower motor com-
NOTE FOR HIGH LIMIT THERMOCOUPLES: partment. Leads from these screw terminals con-
These ovens have a high limit thermocouple installed in nect to the temperature controller at the front of the
the last mounting hole at the exit end of the oven. oven.
The thermocouple supplied in this Kit can be used to The ground leads for temperature-sensing thermo-
replace ANY of the temperature-sensing or high limit ther- couples are connected to the chassis ground lug
mocouples on the oven. inside the left blower motor compartment.
4. Remove and discard the thermocouple.
1. Remove the rear shrouds and blower motor covers. This
allows access to the thermocouples (on the rear wall) 5. Install the new thermocouple into the original mounting
and screw terminals (inside the blower motor compart- hole. Fasten it in place with the supplied #6 x 3/8”
ments). screws.
2. Remove the screws that hold the thermocouple to the 6. Wire the thermocouple as shown in Figure 9.
wall. Slide the thermocouple out of its mounting hole.
6. Use the kit-supplied nylon clamp and #10-16 x 3/4”
screw to secure the thermocouple leads so that they
will clear the shrouds, blower belts, and pulleys.
7. Close the machinery compartment door. Replace all
shrouds onto the oven.

Figure 9
Thermocouple Wiring - PS555

Temperature-sensing
thermocouple ground
leads attach to
ground lug

Cap

Screw terminals:
1 for red leads
1 for white leads
2 total

Red White
Temperature-sensing
thermocouple leads
(red or white)
+ Shielded
1 lead to temperature ground lead
controller

High limit
thermocouple leads
attach directly to high
limit control module
6

61
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kits 33984 and 33985 -

Oven Thermocouple Kit, 11/01
PS555 Electric and PS555E Note that all of the rear wall thermocouples are con-
nected to the terminal block inside the left blower mo-
Temperature-sensing thermocouples on these ovens are lo- tor compartment. It is not necessary to access the
cated on the rear wall. High limit thermocouples are lo- right blower motor compartment.
cated inside the machinery compartment. All thermo-
couples are secured in place by two screws that are in- 2. Remove the screws that hold the thermocouple to the
serted through the holes in the thermocouple flange. These wall. Slide the thermocouple out of its mounting hole.
ovens are equipped with a three-lead, flanged thermocouple 3. Disconnect the thermocouple leads. Rear wall ther-
identical to the one in this Kit. mocouples are connected to the terminal block inside
NOTE FOR HIGH LIMIT THERMOCOUPLES: the left blower motor compartment. High limit thermo-
PS555E electric ovens are equipped with a high limit ther- couples are connected directly to the high limit control
mocouple at the front of the oven, inside the machinery module.
compartment. All other PS555E, PS555G and PS570G 4. Remove and discard the thermocouple.
ovens have a high limit thermocouple installed into the
rear wall in the last mounting hole at the exit end of the 5. Install the new thermocouple into its mounting hole.
oven. Fasten it in place with the supplied #6 x 3/8” screws.
The thermocouple supplied in this Kit can be used to 6. Wire the thermocouple as shown in Figure 10.
replace ANY of the temperature-sensing or high limit ther-
mocouples on the oven. 7. If you replaced a rear wall thermocouple, use the kit-
supplied nylon clamp and #10-16 x 3/4” screw to se-
1. If you will be replacing the high limit thermocouple, open cure the thermocouple leads so that they will clear the
the machinery compartment door. shrouds, blower belts, and pulleys.
To replace any other thermocouple, first remove the
rear shrouds. Then, remove the cover over the left blower 8. Replace all shrouds onto the oven. Close the machin-
motor. This allows access to the thermocouples on ery compartment door.
the rear wall, and to the terminal block inside the blower
motor compartment.

Figure 10
Thermocouple Wiring - PS555 Electric and PS555E

Temperature-sensing Temperature-sensing
thermocouple leads thermocouple leads
Ground Red White
Red White leads

Shielded
ground lead

Left
Terminal
Block
High Limit
Control
Module

To temperature To ground
controller terminal on temp
controller

62
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kits 33984 and 33985 -

Oven Thermocouple Kit, 11/01
PS570 (X01-X05 name plate ID numbers) and 7. Refer to Figure 11. Measure and scribe marks in the
PS570S (early) with side-mounted thermo- rear wall of the oven for drilling the thermocouple mount-
ing holes. Make sure that your measurements begin
couples inside or outside the blower motor at the edges of the rear panels, and NOT at the outer
compartments edges of the oven!
These ovens are equipped with two thermocouples, one on Note that there are two different thermocouple placement
each end wall of the oven. The thermocouples may be locations: one for Pizza Hut (and Pizza Hut International,
mounted either inside or outside of the blower motor com- or Tricon) ovens, and one for all other ovens.
partments.
8. Drill the new thermocouple mounting holes using an
• The thermocouple on the right side of the oven has two 11/32” (8.73mm) D x 8” (203mm) L bit. Make sure that
leads and sends its signal to the temperature controller. you drill through all three walls of the oven.
• The thermocouple on the left side of the oven is a dual-
9. Drill the two screw mounting holes for each thermo-
function unit. It has FOUR LEADS and sends indi-
couple using a 7/64” (2.78mm) bit. Tap the holes using
vidual signals to the temperature controller and the high
a #6-32 tap.
limit control module.
Installing this Kit will replace BOTH thermocouples with 10. If necessary, remove air fingers from the oven to ac-
current three-lead versions located on the back wall of the cess the areas around the new thermocouple mount-
oven. The Kit also requires the installation of a THIRD ther- ing holes.
mocouple to act as a high limit sensor. Because of this, 11. Vacuum out ALL drill shavings. If the oven is equipped
you will need three separate thermocouple kits for these with a screen over the openings for the lower air fin-
ovens. gers, use a flexible hose extension on the vacuum to
If the oven has already been updated with the rear-wall ther- reach the shavings through the upper air finger open-
mocouple configuration, you can simply replace the affected ings.
thermocouple. Follow the instructions for PS570S (late)
rear wall thermocouples on Page 10. 12. Reinstall the air fingers and end plugs onto the oven.

1. If the thermocouples are located outside the blower 13. Install the three new thermocouples into the back wall
motor compartments, remove and retain the thermo- of the oven. Check that the thermocouple flanges are
couple covers. flush with the back wall.

2. Remove the end plugs from the oven. Then, remove 1 14. Secure each thermocouple in place with the two kit-
or 2 air fingers from each end of the oven as necessary supplied #6 x 3/8” screws.
to access the thermocouple mounting tubes. 15. Wire the thermocouples as shown in Figure 12. The
3. Remove the rear shrouds. Open the blower motor com- thermocouples should be wired to the terminal block
partment doors. inside the blower motor compartment closest to the
thermocouple.
4. Remove the cooling fans from both blower motors. Then,
remove the blower belts. IMPORTANT
5. For each thermocouple: As you wire the thermocouples, be sure to connect a
single chassis ground wire to the mounting screw for the
• Disconnect the thermocouple leads from the ter- terminal block. See Figure 12.
minal block inside the blower motor compartment.
A good ground connection for the thermocouple’s
• Remove and discard the screws that hold the ther- uninsulated lead is REQUIRED for proper operation!
mocouple mounting tube to the plenum wall. Re-
move and discard the thermocouple and tube. 16. If you will be replacing additional thermocouples, re-
• Plug the internal and external openings left by the peat Steps 7-15 as necessary.
tubes using a high-temperature silicone sealant.
17. Using the kit-supplied nylon clamps and #10-16 x 3/4”
6. If the thermocouples were located outside the blower screws, secure the thermocouple leads to the back
motor compartments, replace the thermocouple cov- wall of the oven so that they will clear the shrouds,
ers. blower belts, and pulleys.
18. Replace the blower belts and cooling fans.
19. Close the blower motor compartment doors. Replace
all shrouds onto the oven.

63
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kits 33984 and 33985 -

Oven Thermocouple Kit, 11/01
Figure 11
Location of New Thermocouple Mounting Holes - PS570, PS570S

High limit thermocouple High limit thermocouple

position for ovens with position for ovens with
LEFT-TO-RIGHT conveyors Thermocouple positions RIGHT-TO-LEFT conveyors
for non-Pizza Hut/Tricon ovens

Thermocouple positions
for Pizza Hut/Tricon ovens

Figure 12a
Thermocouple Wiring - PS570 and PS570S (early) after thermocouple update - Left to Right Conveyor
Left Ground White Red Red White Ground Red White Right
Terminal lead (temp) (temp) (temp) (temp) leads (all) (hi lim) (hi lim) Terminal
Block Block

New chassis
To temperature ground wire To temperature To high limit
controller controller control module

Figure 12b
Thermocouple Wiring - PS570 and PS570S (early) after thermocouple update - Right to Left Conveyor

Left White Red Ground White Red Red White Ground Right
Terminal (hi lim) (hi lim) leads (all) (temp) (temp) (temp) (temp) lead Terminal
Block Block

New chassis
ground wire
To high limit To temperature To temperature
control module controller controller

64
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kits 33984 and 33985 -

Oven Thermocouple Kit, 11/01
PS570S (late) - rear wall thermocouples with 2. Remove the screws that hold the thermocouple to the
left-side AND right-side terminal block connec- wall. Slide the thermocouple out of its mounting hole.
tions 3. Disconnect the thermocouple leads. Remove and dis-
card the thermocouple.
Thermocouples on these ovens are located on the rear wall
and are secured in place by two screws that are inserted 4. Perform Step 4 ONLY if you are installing a high
through the holes in the thermocouple flange. limit thermocouple and no mounting hole is
Most of these ovens have either three or four thermocouples, present. This would be the case if the oven for-
all installed in the back wall of the oven. The thermocouple merly used a four-lead thermocouple to send a
at the extreme exit end of the oven is the high limit thermo- signal to the high limit control module.
couple, while all other thermocouples send their signals to Temperature-sensing thermocouples for these ov-
the digital temperature controller. The thermocouple sup- ens should be installed in the two existing ther-
plied in this Kit can be used to replace ANY of the thermo- mocouple mounting holes.
couples on these ovens. • Refer to Figure 13. Measure and scribe marks in
Some PS570S ovens are equipped with only two thermo- the rear wall of the oven for drilling the high limit
couples. In these ovens: thermocouple mounting hole. Make sure that your
• The thermocouple on the right side of the oven has two measurements begin at the edges of the rear pan-
leads and sends its signal to the temperature controller. els, and NOT and the outer edges of the oven!
• The thermocouple on the left side of the oven is a dual- • Drill the new high limit thermocouple mounting hole
function unit. It has FOUR LEADS and sends indi- using an 11/32” (8.73mm) D x 8” (203mm) L bit.
vidual signals to the temperature controller and the high Be sure to drill through all three walls of the oven.
limit control module. • Drill the two screw mounting holes for the high limit
• Installing this Kit will replace BOTH thermocouples with thermocouple using a 7/64” (2.78mm) bit. Tap the
current three-lead versions located on the back wall of holes using a #6-32 tap.
the oven. The Kit also requires the installation of a • If necessary, remove the end plugs and air fingers
THIRD thermocouple to act as a high limit sensor. Be- from the oven to access the areas around the new
cause of this, you will need three separate thermo- high limit thermocouple mounting hole.
couple kits for these ovens.
• Vacuum out ALL drill shavings. If the oven is
1. Remove the rear shrouds and open the blower motor equipped with a screen over the openings for the
compartment doors. This allows access to the ther- lower air fingers, use a flexible hose extension on
mocouples (on the rear wall) and terminal blocks (in- the vacuum to reach the shavings through the up-
side the blower motor compartments). per air finger openings.
• Reinstall the air fingers and end plugs onto the oven.

Figure 13
Location of High Limit Thermocouple Mounting Hole - PS570S

High limit thermocouple High limit thermocouple

position for ovens with position for ovens with
LEFT-TO-RIGHT conveyors RIGHT-TO-LEFT conveyors

10

65
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kits 33984 and 33985 -

Oven Thermocouple Kit, 11/01
Figure 14a
Thermocouple Wiring - PS570S (Late) - Left to Right Conveyor
Left Ground White Red Red White Ground Red White Right
Terminal leads (temp) (temp) (temp) (temp) leads (all) (hi lim) (hi lim) Terminal
Block Block
NOTE: This configuration
shows leads for three
temperature-sensing
thermocouples - two on the
left side, and one on the
right. Ovens with only two
temperature-sensing
thermocouples will have a
single set of leads on the
left terminal block, instead
of the two sets that are
shown.
To temperature To high limit
To ground To temperature controller To ground To mounting screw control module
terminal on temp controller terminal on temp for high limit
controller controller control module

Figure 14b
Thermocouple Wiring - PS570S (Late) - Right to Left Conveyor

Left White Red Ground White Red Red White Ground Right
Terminal (hi lim) (hi lim) leads (all) (temp) (temp) (temp) (temp) leads Terminal
Block Block
NOTE: This configuration
shows leads for three
temperature-sensing
thermocouples - two on the
right side, and one on the
left. Ovens with only two
temperature-sensing
thermocouples will have a
single set of leads on the
right terminal block,
instead of the two sets
that are shown. To high limit To temperature
control module To mounting screw To ground controller To temperature To ground
for high limit terminal on temp controller terminal on temp
control module controller controller

5. Install the new thermocouple into its mounting hole. 7. If you will be replacing additional thermocouples, re-
Fasten it in place with the supplied #6 x 3/8” screws. peat Steps 2-6 as necessary.
6. Wire the thermocouple as shown in Figure 14. The 8. Use the kit-supplied nylon clamp and #10-16 x 3/4”
thermocouples should be wired to the terminal block screw to secure the thermocouple leads so that they
inside the blower motor compartment closest to the will clear the shrouds, blower belts, and pulleys.
thermocouple.
9. Close the machinery compartment and blower motor
IMPORTANT compartment doors. Replace all shrouds onto the oven.
As you wire the thermocouples, check that ground leads Figure 15
run from the terminal blocks inside the blower motor com- Alternate ground lead wiring
partments to BOTH the temperature controller AND the Use ONLY if ground leads to front compartment are not present.
high limit control module, as shown in Figure 14.
White Red Ground White Red
If the ground leads to the front compartment of the oven (hi lim) (hi lim) leads (all) (temp) (temp)
are NOT present - for example, on an oven that previ-
ously used the older-style 2-lead or 4-lead thermocouples
- it is acceptable to use a single chassis ground wire to
the mounting screw for the terminal block. See Figure
15.
A good ground connection for the thermocouple’s
uninsulated lead is REQUIRED for proper operation!

New chassis
ground wire
To high limit To temperature
control module controller
11

66
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kits 33984 and 33985 -

Oven Thermocouple Kit, 11/01
PS555G and PS570G rear wall thermocouples 2. Remove the screws that hold the thermocouple to the
with left-side terminal block connections wall. Slide the thermocouple out of its mounting hole.

Thermocouples on these ovens are located on the rear wall. 3. Disconnect the thermocouple leads from the terminal
They are secured in place by two screws that are inserted block. Remove and discard the thermocouple.
through the holes in the thermocouple flange. The ovens 4. Install the new thermocouple into its mounting hole.
are equipped with a three-lead, flanged thermocouple iden- Fasten it in place with the supplied #6 x 3/8” screws.
tical to the one in this Kit.
5. Wire the thermocouple as shown in Figure 16. Note
NOTE FOR HIGH LIMIT THERMOCOUPLES: that the terminals are labeled - “TC” for temperature-
These ovens have a high limit thermocouple installed in sensing thermocouple leads, “G” for ground leads, and
the last mounting hole at the exit end of the oven. “HL” for high limit thermocouple leads.
The thermocouple supplied in this Kit can be used to
6. Use the kit-supplied nylon clamp and #10-16 x 3/4”
replace ANY of the temperature-sensing or high limit ther-
screw to secure the thermocouple leads so that they
mocouples on the oven.
will clear the shrouds, blower belts, and pulleys.
1. Remove the rear shrouds. Then, remove the cover over 7. Replace all shrouds onto the oven.
the left blower motor. This allows access to the ther-
mocouples on the rear wall, and to the terminal block
inside the blower motor compartment.
Note that the thermocouples on these ovens are all
connected to the terminal block inside the left blower
motor compartment. It is not necessary to access the
right blower motor compartment.

Figure 16
Thermocouple Wiring - PS555G and PS570G

Red White Ground Red White

(temp) (temp) leads (all) (hi lim) (hi lim)

To temperature To high limit

controller To ground To mounting screw control module
terminal on temp for high limit
controller control module

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
12

67
SECTION 3 - SERVICING COMPONENTS
V. BLOWERS Figure 25
A. PS200-series ovens Early-style PS200 indirect drive assembly
All PS200 ovens are equipped with one 1/3hp blower mo-
tor. The motor indirectly drives a pulley on the shaft of the
blower fan with a fan belt.
Two main designs exist for the PS200 indirect fan drive
assembly:
• Early design, used through 6/90. This design used
1/2” (12.7mm) bore flange mount bearings and a 1/2”
(12.7mm) diameter blower fan shaft. See Figure 25.
• Current design, used 7/90 and later. This design uses
5/8” (15.9mm) pillow block bearings and a 5/8” (15.9mm)
diameter blower fan shaft. See Figure 26.
Blower motors on both versions are rated for 208-240V,
Direction of rotation
single-phase, and are protected by: (viewed from
• A built-in thermal overload protection device. rear of oven)

• Two 9A fuses on the inside of the machinery compart-

ment door. Fuse location is shown in Figure 27.
In addition, the blower fan is protected by an air pressure
Figure 26
saftety switch that prevents the burner/heating elements Current PS200 indirect drive assembly
from activating if the fan is not rotating. See Air Pressure
Safety Switch on Page 81.

1. Part number reference

Early version components
NOTE: If an early-version PS200-series oven has a
failed fan shaft, upgrade the oven to the current drive
assembly using Kit P/N 49810-0121.
Part Number Description
22230-0072 Pulley, 1/2” / 12.7mm bore
22071-0019 Bearing, 1/2” / 12.7mm bore, flange Direction of rotation
(viewed from
mount rear of oven)
37900-0094 Fan shaft alignment tool (early)
27381-0066 Motor, 1/3 hp, 200-240V, 50/60Hz ,1 Ph
Figure 27
22181-0034 Fan belt
Blower motor fuses
Current version components Blower
motor
Part Number Description fuses
35900-0232 Shaft, blower fan
22230-0073 Pulley, 5/8” / 15.9mm bore
22072-0025 Bearing, 5/8” / 15.9mm bore, pillow
block mount
27399-0003 Blower fan, 16” / 0.4m diameter
37900-0106 Fan shaft alignment tool (current)
49810-0121 Indirect drive upgrade kit (upgrades
early-style version to current version)
49810-0018 Fan shaft service kit (includes 2 bear- Control
ings, 1 shaft, and alignment tool ) fuse

27381-0066 Motor, 1/3 hp, 200-240V, 50/60Hz ,1 Ph

22181-0034 Fan belt

68
 SECTION 3 - SERVICING COMPONENTS
2. Blower balancing and direction of rotation Figure 28
Proper blower rotation is extremely important. From Bearing lubrication
the rear of the oven, the blower shaft pulley should turn
in a clockwise direction. See Figures 25 and 26. Grease fittings
(1 per bearing,
All blower fans are balanced at the factory. Any fan 2 total)
found to be out of balance should be replaced. Vibra-
tion from an out-of-balance fan can cause poor baking
and premature bearing failure. Note that vibrations can
also be caused by other sources, including defective
motor or blower shaft bearings, loose bearings or mo-
tor mounting bolts, or an incorrectly tensioned fan belt.
3. Lubricating the blower fan shaft bearings

IMPORTANT: Middleby uses two different types

of grease in blower shaft bearings:
• DuPont Krytox® grease is used in some
PS536 ovens. Refer to Service Bulletin MM-
192 (included in the Appendices section of
this chapter) for details on identifying Figure 29
Krytox® bearings. Blower belt tension
• All other ovens use the standard Middleby
1” (25mm)
high-temperature grease, P/N 17110-0015.
vertical
Mixing grease types within the bearing will deflection
cause the bearing to seize. For all PS200 ov-
ens, be sure to use ONLY the standard
Middleby grease.

NOTE: Middleby recommends lubricating the blower

fan shaft bearings every three months.
Use a grease gun to lubricate the main blower fan shaft
bearings. See Figure 28. When lubricating the bear-
ings:
• Use a high-quality NLGI #2, lithium soap grease with
petroleum oil, such as Middleby P/N 17110-0015.
• Add the grease slowly until a small bead of grease
is present at the seals. AVOID OVERGREASING.
Excessive greasing may cause harm to the bearing. Figure 30
Manually turn the blower shaft by pulling on the belt to Repositioning the blower motor
purge the grease. Wipe off any excess grease. The
oven cannot be operated until the rear shroud is replaced.
4. Blower belt tension
NOTE: Middleby recommends checking the blower
belt condition and tension every three months.
Check the blower belt for at least 1" (25mm) deflection
at the center, and for cracking or excessive wear.
Overtightening the belt will cause premature bearing
failure and possible vibrations. See Figure 29.
If necessary, adjust the tension of the belt by loosening
the two motor mounting bolts as shown in Figure 30.
Reposition the motor as neccessary until the correct
deflection is reached, then tighten the bolts.
Loosen bolts to
reposition motor
and adjust belt
tension
69
SECTION 3 - SERVICING COMPONENTS
5. Early-style PS200 bearing replacement and alignment NOTE: The bracket assembly is designed for slight up
NOTE: This procedure is for early-style indirect fan and down and right to left movement to attain free shaft
shaft assemblies only, as shown in Figure 25. Bearing rotation when the shaft alignment tool is in place. Once
replacement procedures for the current-style indirect free shaft rotation is achieved, tighten all eight bracket
fan shaft assembly (Figure 26) are provided on Page screws (Item 2).
72. 11. Tighten rear flange bearing block screws (Item 11)
then front flange bearing block screws.
IMPORTANT: Before attempting any repair on the
12. Remove shaft alignment tool, then recheck fan shaft
early-style PS200 Indirect Fan Drive Assembly:
for free rotation.
• If you need to perform any maintenance more
13. Install pulley (Item 8) on fan shaft and position fan
involved than replacing and aligning the shaft bear-
shaft per the dimensions shown in Figure 32. Align
ings, you should upgrade the fan shaft assembly
the two flats per bearing which are machined on
to the current version.
fan shaft for the bearing set screws. Use High
• Check the front and rear brackets (Item 6 in Fig- Temperature Loctite, RC 620 on bearing set screws
ure 32). If the brackets ARE NOT welded to- and then tighten set screws. Recheck fan shaft for
gether, you should upgrade the fan shaft assem- free rotation.
bly to the current version.
14. Apply anti-seize compound on fan shaft before in-
In either of these cases, you can upgrade the fan stalling fan blade (Item 13). Position fan blade per
shaft assembly using Service Kit P/N 49810-0121. dimension shown in Figure 32.
See Part Number Reference on Page 68 for details.
15. Apply High Temperature Loctite Type RC 620 to
The following procedures are necessary to align the fan blade set screws.
fan shaft whenever service to the fan shaft or replace- NOTE: Tighten the two set screws on fan blade per
ment of the bearings is required. REFER TO FIGURE the following sequence when viewing fan blade from
32 FOR ILLUSTRATIONS OF THE COMPONENTS DE- front: first, the screw at the 12:00 position, then the
SCRIBED HERE. screw at the 3:00 position.
1. Remove the entire back wall (Item 1) of oven to 16. Recheck fan shaft rotation before installing back
service the fan assembly. wall to oven cavity.
2. Remove the blower fan (Item 13) and pulley (Item NOTE: Apply anti-seize compound (MM P/N 17110-
8). 0017) to all 12 bolts before installing back wall assem-
NOTE: If parts are to be replaced, you should replace bly to oven.
them now. 17. Install back wall on oven.
3. When installing the Drive Bracket Assembly (Item 18. Install fan belt.
5) insert one 3/8” flat washer (Item 4) at the 4 outer NOTE: Excessive fan belt tension will create overload-
holes and one 3/8” special flat washer (Item 14) at ing of rear bracket fan shaft bearing. Refer to Blower
the 4 inner holes between bracket and back wall at Belt Tension on Page 69.
mounting locations. Use eight 3/8”-16 x 1” screws
(Item 2) and assemble a 3/8” lockwasher (Item 3)
Figure 31
and a 3/8” flat washer (Item 4) onto each screw.
Insert a screw at all 8 locations, hand tighten only Fan shaft alignment tool
at this time.
4. Install front and rear fan shaft flange bearings (Item
10), if they were removed, to Indirect Drive Bracket
(Item 6) using three 1/4-20 x 3/4” screws (Item 11)
and three 1/4” lockwashers (Item12) on each bear-
ing.
IMPORTANT: The bearings (10) must be mounted
so the grease fitting faces up when the bracket
assembly (Item 5) is mounted on the rear wall.
NOTE: Do not tighten flange bearing block screws
until Step 10 has been completed.
9. Install the fan shaft as shown in Figure 32. Align
bearing set screws with flats on shaft but do not
tighten set screws at this time.
10. Insert fan shaft alignment tool (Item 15) into back
wall as shown in Figure 31. 70
 SECTION 3 - SERVICING COMPONENTS

Figure 32
Bearing replacement and alignment - early-style PS200 fan shaft assembly

Item Qty. Part Number Description Item Qty. Part Number Description
1 1 Not available Back Wall Assembly 9 1 21651-0008 Square Key 1/8”
2 8 21216-0001 Screw, Hex Cap SS 3/8-16x1” 10 2 22071-0010 Flange Bearing, 5/8” Bore
3 16 21422-0001 Lock Washer, Split 3/8” 11 6 21211-0004 Screw, Hex Cap 1/4-20 x 3/4”
4 20 21416-0001 Flat Washer, SS 3/8” 12 6 21421-0016 Lock Washer, Split 1/4”
5 1 Not available Indirect Fan Drive Bracket Assembly 13 1 Not available Blower Fan, 16” Dia.
6 1 Not available Bracket, Indirect Drive 14 4 21419-0004 Flat Washer 3/8” SS Special
7 1 Not available Shaft, Fan Drive 15 1 37900-0094 Fan Shaft Alignment Tool
8 1 22230-0072 Pulley, 1/2” Bore

IMPORTANT: If parts listed as “Not Available” require replacement, use Service Kit 49810-0121 to upgrade the fan shaft
assembly to the current version.
71
SECTION 3 - SERVICING COMPONENTS
6. Current-style PS200 bearing replacement and alignment 7. Insert fan shaft alignment tool (Item 13) as shown
NOTE: This procedure is for current-style indirect fan into back wall.
shaft assemblies only, as shown in Figure 26. Bearing NOTE: The bracket assembly is designed for slight up
replacement procedures for the early-style indirect fan and down and right to left movement to attain free shaft
shaft assembly (Figure 25) are provided on Page 70. rotation when the shaft alignment tool is in place. Once
The following procedures are necessary to align the free shaft rotation is achieved, tighten all eight bracket
fan shaft whenver service to the fan shaft or replace- screws (Item 2).
ment of the bearings is required. REFER TO FIGURE 8. Tighten rear pillow block bearing screws (Item 9)
34 FOR ILLUSTRATIONS OF THE COMPONENTS DE- then front pillow block bearing screws.
SCRIBED HERE. 9. Remove shaft alignment tool, then recheck fan shaft
1. Remove the entire back wall (Item 1) of oven to for free rotation.
service the fan assembly. 10. Install pulley (Item 7) on fan shaft and position fan
2. Remove the blower fan (Item 11) and pulley (Item shaft per dimension shown in Figure 34. Align the
7). flats machined on fan shaft with the bearing set
3. Remove the indirect drive bracket assembly (Item screw holes. Apply High Temperature Loctite, type
5) by removing eight (8) screws (Item 2). lf you are RC 620 on bearing set screws and then tighten set
upgrading from the early-style assembly, save the screws. Recheck fan shaft for free rotation.
hardware (Items 2, 3, 4, and 12) to be reused with 11. Apply anti-seize compound on fan shaft before in-
the new style bracket (Item 5). stalling fan blade (Item 11). Position fan blade flush
NOTE: If parts are to be replaced, you should replace with 5/8” shoulder on shaft as called out in Figure
them now. 34.
4 Install front and rear fan shaft pillow block bearings NOTE: Fan blade hub has a 1/2” bore. The fan shaft
(Item 9), if they were removed, to indirect drive is turned down from 5/8” to 1/2” to receive fan blade.
bracket (Item 5) using two (2) 3/8-16 X 1” screws 12. Apply High Temperature Loctite Type RC 620 to
(Item 2) and two 3/8” lockwashers (Item 10) on each fan blade set screws.
bearing. NOTE: Tighten the two set screws on fan blade per
NOTE: Do not tighten the pillow block bearings the following sequence when viewing fan blade from
until Step 7 has been completed. front: first, the screw at the 12:00 position, then the
5. Install the fan shaft (Item 6) as illustrated in Figure screw at the 3:00 position.
34. Align bearing set screws with flats on shaft but 13. Recheck fan shaft rotation before installing back
do not tighten set screws at this time. wall to oven cavity. Be sure fan assembly has ad-
NOTE: Before proceeding to Step 6, it is advisable to equate clearance inside orifice ring and is not rub-
position the rear wall assembly in an upright, vertical bing.
position using a block of wood under the fan ring. NOTE: Apply anti-seize compound (MM P/N 17110-
6. When installing the drive bracket (Item 5) insert 0017) to all 12 bolts before installing back wall assem-
one 3/8” flat washer (Item 4) at the four outer holes bly to oven.
and one 3/8” special flat washer (Item 12) at the 4 14. Install back wall on oven.
inner holes between the bracket and back wall at 15. Check motor pulley and fan pulley alignment. See
the mounting locations. Use eight 3/8-16 X 1” Figure 33.
screws (Item 2) and assemble a 3/8” lockwasher
(Item 3) and a 3/8” flat washer (Item 4) into each 16. Install fan belt.
screw. Insert a screw at all 8 locations. Hand NOTE: Excessive fan belt tension will create overload-
tighten only at this time. ing of rear bracket fan shaft bearing. Refer to Blower
Belt Tension on Page 69.

Figure 33 - Four-point alignment test for correct pulley alignment

Cord tied to shaft

Cord must touch sheaves at four points indicated by arrows

72
 SECTION 3 - SERVICING COMPONENTS

Figure 34
Bearing replacement and alignment - current-style PS200 fan shaft assembly

Item Qty. Part Number Description Item Qty. Part Number Description
1 1 37900-0068 Back Wall Assembly 11 1 27399-0003 Blower Fan, 16” Dia.
2 16 21216-0001 Screw, Hex Cap SS 3/8-16x1” 12 4 21419-0004 Flat Washer 3/8” SS Special
3 16 21422-0001 Lock Washer, Split 3/8” 13 1 37900-0106 Fan Shaft Alignment Tool
4 12 21416-0001 Flat Washer, SS 3/8”
Also available:
5 1 37900-0101 Bracket, Indirect Drive
-- -- 49810-0018 Fan Shaft Service Kit
6 1 35900-0232 Shaft, Fan Drive Includes Qty. 2 of Item 9 and Qty. 1 ea.
7 1 22230-0073 Pulley, 5/8” Bore of Items 6 and 13.
8 1 21651-0008 Square Key 3/16” -- -- 49810-0021 Fan Shaft Upgrade Kit
9 2 22072-0025 Pillow Block Bearing, 5/8” Bore Includes parts and instructions to up-
date early-style fan shaft assembly to
10 4 21422-0001 Lock Washer, Split 1/4” the current version shown here.

73
SECTION 3 - SERVICING COMPONENTS
B. PS360-series ovens Figure 35
All PS360-series ovens are equipped with two blower motors. Blower motor fuses - single-phase motors
• All gas ovens have motors rated at 230V, single-phase. Left motor Right motor
• All electric ovens built before 8/02 have three-phase fuses - 9A fuses - 9A
motors.
• All electric ovens built 8/02 or later that operate on a Control
fuse - 5A
supply voltage of 208-240V have single-phase motors.
• All electric ovens built 8/02 or later that operate on supply
voltages above 240V have three-phase motors.
Blower motors are protected by:
• A built-in thermal overload protection device.
• For ovens with single-phase blower motors: Two 9A
fuses. Fuse location is shown in Figure 35.
• For ovens with three-phase blower motors: Three 5A
fuses. Fuse location is shown in Figure 36.
In addition, each motor contains a centrifugal safety switch
that prevents the burner/heating elements from activating if
either motor is not operating. See Blower Motor Centrifugal
Safety Switch on Page 80.
The blower wheel is directly connected to the motor shaft.
A heat slinger, also mounted on the motor shaft, helps to Figure 36
keep heat away from the motor bearings. If the motor is Blower motor fuses - three-phase motors
stopped when the temperature in the compartment is over
Left motor Right motor
180°F/82°C, the bearings can be damaged. fuses - 5A fuses - 5A
1. Part number reference
Blower motors Control
fuse - 5A
Part Number Description
27381-0023 1 Ph, 1/3 hp (PS310, -314, -360, -360S)
27381-0024 3 Ph, 1/3 hp (PS310, -314, -360)
27381-0054 1 Ph, 1/4 hp (PS360Q)
27381-0075 1 Ph, 1/2 hp (PS360WB)
31432 1 Ph, 1 hp (PS360EWB, -WB70)

Blower wheels
Part Number Part Number
(clockwise) (counter-clockwise) Description
22523-0002 22523-0003 9-3/16” / 233mm dia. (PS310, -314,
-360, -360Q, -360S, -360WB)
35603 35604 9-1/8” / 232mm dia. (PS360EWB)
36014 36015 8-1/4” / 210mm dia. (PS360EWBQ)
31599 31600 9-7/8” dia. / 251mm (PS360WB70) Transformer fuses
(480V electric
Other components ovens only)
Part Number Description
27396-0005 Heat slinger
42400-0101 Blower wheel puller tool

2. Blower balancing
All blower wheels are balanced at the factory. Any
blower wheel found to be out of balance should be re-
placed. Vibration from an out-of-balance wheel can
cause poor baking and premature motor bearing fail-
ure. Note that vibrations can also be caused by other
sources, including defective motor bearings and loose
motor mounting bolts.
74
 SECTION 3 - SERVICING COMPONENTS
3. Direction of blower rotation 4. Removing the blower wheels
Proper blower rotation is extremely important. Blower To change a motor or blower wheel, the wheel must
rotation is determined by viewing the motor and wheel first be removed from inside the oven as follows:
from the REAR of the motor (or from the open end of • Remove the end plugs and conveyor assembly.
the oven). See Figures 37-39.
• From inside the oven cavity, reach into the blower
recess and remove the inlet rings. See Figure 40.
Figure 37 - Clockwise blower wheel
• Loosen the set screw on the blower wheel hub and
Heat slinger Direction remove the blower wheel. A special wheel puller
blades face motor of rotation tool (P/N 42400-0101) is available for this purpose.
See Figure 41.

IMPORTANT: Before installing the new wheel,

apply an anti-seize lubricant (Middleby P/N 17110-
0017) to the motor shaft and the inside of the blower
wheel hub.

Note slant of blades

Figure 40
(rear view) Inlet ring

Figure 38 - Counterclockwise blower wheel

Direction
of rotation Heat slinger
blades face motor

Note slant of blades

(rear view)

Figure 41
Figure 39 - Blower wheel placement Blower wheel puller tool
Shown from rear of oven
Counter-
Clockwise clockwise
Upper right Upper left

Counter- Clockwise
clockwise Lower left
Lower right
75
SECTION 3 - SERVICING COMPONENTS
A. PS555/570-series ovens The two designs share many common parts, including blower
All PS555/570-series ovens are equipped with two 1hp blower wheels, motors, and bearings. From a service standpoint,
motors. Each motor indirectly drives a pulley on the shaft the major difference is the size of the pulleys and the length
of a blower wheel with a fan belt. of the belts.
Two main designs exist for the PS555/570 blower fan sys- Blower motors on all PS555/570-series ovens are rated for
tem: 208-240V, single-phase, and are protected by:
• PS570/570S design. In this version, the pillow block • A built-in thermal overload protection device.
bearings for the blower wheel shaft were mounted up- • Two 15A fuses or 15A circuit breakers. Refer to Figure
right, on brackets that were parallel to the fan belts. 44 for the location of the fuses/breakers.
See Figure 42. In addition, each blower fan is protected by an air pressure
• PS555/570G design. In this version, the pillow block saftety switch that prevents the burner/heating elements
bearings are mounted with the grease fittings pointing from activating if the fan is not rotating. See Air Pressure
in towards the center of the oven. See Figure 43. Safety Switch on Page 81.

Figure 42 - PS570/570S blower configuration

Belt
Blower
motor Direction
of rotation
Pulley

Bearing Blower Pulley Blower wheel

shaft (inside oven)

Figure 43 - PS555/570G blower configuration

Belt
Blower
motor

Pulley

Bearing Blower Pulley Blower wheel

shaft (inside oven)

Figure 44 - Fuse/circuit breaker locations

PS555 (current),
PS570/570S: PS555 (early): PS570G: 15A
15A fuses located on 15A breakers located breakers located on
left side of machinery inside left blower right side of machinery
compartment motor compartment compartment
76
 SECTION 3 - SERVICING COMPONENTS
1. Part number reference Part Number Description
Part Number Description 22072-0026 Bearing, pillow block, 1” / 25.4mm bore
(PS570)
27381-0069 Motor, 1 hp, 208-240V, 50/60 Hz, 1 Ph
22072-0017 Bearing, pillow block, 1-7/16” / 36.5mm
22521-0005 Blower wheel, clockwise (right end of
bore (PS570S)
PS570; left end of PS555, PS570S,
PS570G) 35210-0251 Blower shaft, 1” dia. (PS570)
22521-0006 Blower wheel, counterclockwise (left end 35210-0506 Blower shaft, 1-7/16” dia. (PS570S)
of PS570; right end of PS555, PS570S, 41899 Blower shaft, 1-7/16” dia. (PS555 or
PS570G) PS570G)

Oven Blower Pulley Motor Pulley Belt Blower

Application model Hz Part No. Desc. Part No. Desc. Part No. Desc. RPM
Standard PS570 60 22230-0084 BK52 30476 BK47 22181-0037 -- --
PS570S 60 22230-0087 BK47H 30476 BK47 46744 BX55 1780 RPM
PS570S 50 22230-0087 BK47H 22230-0086 BK55 46745 BX56 1733 RPM
PS570G 60 39587 BK70 44977 BK70 46452 BX67 1780 RPM
PS555/ 60 39587 BK70 39586 BK80 44946 BX61 2080 RPM
555G/555E
Pizza Hut PS570S 60 22230-0087 BK47H 22230-0086 BK55 46745 BX56 1733 RPM
USA
PS570S 60 22230-0087 BK47H 39910 BK62 44963 BX58 2300 RPM
High Altitude
PS570G 60 39587 BK70 39586 BK80 46453 BX68 2057 RPM
PS570G 60 39587 BK70 46455 BK90 46454 BX70 2300 RPM
High Altitude
Pizza Hut PS570S 60 22230-0087 BK47H 22230-0086 BK55 46745 BX56 1733 RPM
Intl. (Tricon)
PS570G 60 39587 BK70 39586 BK80 46453 BX68 2057 RPM
PS555G 50 39587 BK70 42984 BK95H 47044 BX62 2020 RPM
22031-0001 bushing
PS555E 50 39587 BK70 39586 BK80 44946 BX61 1680 RPM
Domino’s “Q” PS570S 60 22230-0087 BK47H 45796 BK45 46744 BX55 1692 RPM
PS570G 60 39587 BK70 47267 BK65 46452 BX67 1692 RPM
PS555G 60 39587 BK70 39910 BK62 44963 BX58 1580 RPM
Papa John’s PS555G 60 39587 BK70 39910 BK62 44963 BX58 1580 RPM

NOTE: If a particular customer/oven model combination is not listed (for example, Pizza Hut PS555G), use the
“Standard” information.

77
SECTION 3 - SERVICING COMPONENTS
2. Blower balancing and direction of rotation Figure 45
Proper blower rotation is extremely important. Proper PS500-series blower wheel orientation
blower rotation is shown in Figure 45.
Clockwise: PS570: Counter-
Early PS570 blower wheels were positioned so that Right end Open end of wheel faces IN clockwise:
the open end of the wheel faced into the baking cham- Left end
ber. This was changed on the PS570S (and all later
models) to improve airflow. Note that this also means
that on early PS570 ovens the counterclockwise wheel
is moved to the left side of the oven, and the clockwise
wheel moved to the right side, so that the wheel blades
point in the same direction. This is reflected in the
Part Number Reference information on Page 77.
All blower wheels are balanced at the factory. Any
blower wheel found to be out of balance should be re-
placed. Vibration from an out-of-balance wheel can
Counter- PS570S, PS570G, PS555: Clockwise:
cause poor baking and premature bearing failure. Note clockwise: Open end of wheel faces OUT Left end
that vibrations can also be caused by other sources, Right end
including defective motor or blower shaft bearings, loose
bearings or motor mounting bolts, or an incorrectly
tensioned fan belt.

3. Lubricating the blower shaft bearings

IMPORTANT: Middleby uses two different types

of grease in blower shaft bearings:
• DuPont Krytox® grease is used in some
PS536 ovens. Refer to Service Bulletin MM-
192 (included in the Appendices section of
this chapter) for details on identifying
Krytox® bearings.
Note slant of blades
• All other ovens use the standard Middleby
high-temperature grease, P/N 17110-0015.
Mixing grease types within the bearing will
cause the bearing to seize. For all PS555/570-
series ovens, be sure to use ONLY the stan-
Figure 46
dard Middleby grease. Bearing lubrication
Grease fittings
NOTE: Middleby recommends lubricating the blower (1 per bearing,
fan shaft bearings every three months. 4 total)
Use a grease gun to lubricate the main blower fan shaft PS570,
bearings. See Figure 46. When lubricating the bear- PS570S
ings:
• Use a high-quality NLGI #2, lithium soap grease with
petroleum oil, such as Middleby P/N 17110-0015.
• Add the grease slowly until a small bead of grease
is present at the seals. AVOID OVERGREASING. Grease fittings
Excessive greasing may cause harm to the bearing. (1 per bearing,
4 total)
Manually turn the blower shaft by pulling on the belt to
purge the grease. Wipe off any excess grease. The
oven cannot be operated until the rear shroud is replaced.

PS570G,
PS555

78
 SECTION 3 - SERVICING COMPONENTS
4. Blower belt tension Figure 47
NOTE: Middleby recommends checking the blower Blower belt tension and
belt condition and tension every three months. repositioning the blower motor
Check the blower belt for at least 1" / 25mm deflection
at the center, and for cracking or excessive wear.
Overtightening the belt will cause premature bearing
failure and possible vibrations. See Figure 47.
PS570,
If necessary, adjust the tension of the belt by loosening
PS570S
the two motor mounting bolts as shown in Figure 47.
Reposition the motor as neccessary until the correct
deflection is reached, then tighten the bolts.

1” (25mm)
5. Bearing replacement and alignment vertical
deflection
Whenever service to the blower shaft or replacement of
the bearings is required, the shaft will need to be aligned.
NOTE: Apply anti-seize compound (MM P/N 17110-
0017) to all bolts before installing back wall assembly
to oven. PS570G,
PS555
First, reassemble the back wall components, but DO
NOT TIGHTEN THE HEX BOLTS that hold the bearings
to their mounting brackets. Leaving the bearings loose
allows the pulleys to be aligned.
Next, check the alignment of the pulleys using a cord
as shown in Figure 48. Reposition the bearings as
required to align the blower shaft, then tighten the hex
bolts to hold the shaft in place.
Replace the belts and rear shrouds after the pulleys
Loosen bolts to
are properly aligned. reposition motor
and adjust belt
tension

Figure 48 - Four-point alignment test for correct pulley alignment

Cord tied to shaft

Cord must touch sheaves at four points indicated by arrows

79
SECTION 3 - SERVICING COMPONENTS
VI. BLOWER MOTOR CENTRIFUGAL SAFETY SWITCH VII. BURNER BLOWER MOTOR CENTRIFUGAL SAFETY
(PS360-SERIES) SWITCH (PS200-SERIES GAS, PS310, PS314,
Middleby ovens have a safety feature that prevents the PS360, PS360WB, PS570S)
burner/heating elements from activating if the blower(s) are Middleby gas ovens with a 120V burner blower motor have
not in operation. On PS360-series ovens, this feature is a centrifugal safety switch that prevents burner activation if
controlled by a centrifugal switch mounted inside each the burner blower motor is not in operation. This includes:
blower motor. If either motor is not operating, the burner/ • Most PS360-series ovens (except PS360WB70 and
heating elements cannot activate. PS360EWB);
The centrifugal switch is a normally-closed (NC) limit switch • PS200-series gas ovens (except units produced with
mounted inside the rear of each blower motor. See Figure the modulating gas system);
49. When the motor is not running, the centrifugal switch
weight holds the switch open. As the motor reaches full • All Model PS570S ovens.
speed, the weight moves away from the switch permitting Ovens with a 208/240V burner blower motor use a separate
the contacts to close. When the switch contacts of BOTH air pressure safety switch to prove motor operation. See
blower motors are closed, the heat circuit is completed, Air Pressure Safety Switch on Page 81.
allowingthe burner/heating elements to activate. The centrifugal switch is a normally-closed (NC) limit switch
If a blower motor is not operating, the switch will not close mounted inside each blower motor. When the motor is not
and the circuit remains open, preventing burner/heating el- running, the centrifugal switch weight holds the switch open.
ement activation. As the motor reaches full speed, the weight moves away
A. Part Number Reference - Blower Centrifugal Switch from the switch permitting the contacts to close. This com-
pletes the heat circuit, allowingthe burner to light.
On all PS360-series blower motors, the centrifugal
switch can be replaced with switch P/N 27270-0144. If the burner blower motor is not operating, the switch will
not close and the circuit remains open, preventing burner
B. Troubleshooting activation.
1. To access the switch, remove the rear motor wiring No adjustment can be made to the switch. If it is not oper-
cover plates. See Figure 49. ating properly, the burner blower motor must be replaced.
2. When the switch is operating properly, both sides of
the brown wires coming from the switch should be “hot”
when the motor is at full RPM.
3. No adjustment can be made to the switch. If it is not
operating properly, it must be replaced.

Figure 49 - PS360-series blower motor centrifugal safety switch

Switch

80
 SECTION 3 - SERVICING COMPONENTS
VIII. AIR PRESSURE SAFETY SWITCH (PS200-SERIES, because of the presence of a centrifugal air switch inside
PS555/570-SERIES, PS360EWB, PS360WB70) the motor housing (see Section VII, Burner Blower Motor
Middleby ovens have a safety feature that prevents the Centrifugal Safety Switch, on the previous page).
burner/heating elements from activating if the blower(s) are The switch is an assembly that includes a normally-open
not in operation. On PS200-series ovens and PS555/570- microswitch and a diaphragm. When the blower is at speed,
series ovens, this feature is controlled by a separate air pressure is applied to the diaphragm which in turn closes
pressure switch that reads air flow from the blower. One the microswitch. This completes the heat circuit, allowing
switch is used for each blower (1 for the PS200-series, 2 the burner/heating elements to activate.
for the PS555/570 series). If a blower is not operating, the microswitch receives no
These ovens cannot use a centrifugal switch on the motor signal from the diaphragm and cannot close, preventing
because they use an indirect, belted drive system. If a belt burner/heating element activation.
fails, it is possible for the motor to operate normally while A. Part Number Reference - Air Switches
the blower itself is stopped.
Middleby has used four different types of air switches for
In addition, gas ovens with a line-voltage burner blower mo- these applications. See Figure 50.
tor use an identical air switch to check that the burner blower
motor is operating before burner activation. These ovens When replacing one of these switches, note that the “cur-
include the PS360EWB, PS360WB70, PS555, PS555G, rent” Yamatake-Honeywell air switch (#4 below) cannot be
and PS570G, as well as PS200-series ovens equipped with used as an upgrade for an older switch. If you are replacing
the modulating gas system. This additional air switch is Switches #1, #2 or #3 as shown in Figure 50, you should
not necessary on ovens with a 120V burner blower motor use the Service Kits described for Switch #2.

Figure 50 - Air pressure safety switch models

1. 2.
Original-style round air switch Dungs square-case air switch with dial adjustment
Replace with #2 Replace with same
Positive
pressure Adjustment dial
(in. W.C. or
mbar)
Adjustment
screw

Positive
pressure

Negative
pressure

3. 4.
Dungs square-case “replacement” air switch with screw adjustment Yamatake-Honeywell air switch, non-adjustable
Replace with #2 Replace with same

Adjustment
screw

Adjustment
screw
(fixed at proper
Positive setting - cannot
pressure be adjusted)

Negative
pressure
Positive Negative
pressure pressure
81
SECTION 3 - SERVICING COMPONENTS
1. Original-style round air switch with screw adjustment • Domestic switch: P/N 39530
(P/N 28023-0005) • CE-version switch: P/N 37498
This was the standard switch used through 9/96 and is If this switch must be replaced, use an identical switch.
no longer available. If it must be replaced, use Kit P/N Note that this is the ONLY time that you may use P/Ns
35624 (for use in the USA) or 35625 (for export use). 39530 and 37498 as service replacement parts.
See #2 below for a description of these kits.
B. Troubleshooting
2. Dungs square-case air switch with dial adjustment
1. Postive pressure vs. negative pressure
This was the standard switch used from 9/96 through All air switches except the original round version can
1/02. It cannot be upgraded to the current Yamatake- sense either positive air pressure or negative air pres-
Honeywell octagonal switch, and so should still be used sure. The connection that is actually made to the switch
as a service replacement. EXCEPTION: PS570G and depends on the application.
all PS555 ovens have used the Yamatake-Honeywell
• If the switch is used to detect blower operation, the
switch throughout their production run (see #4 below).
tip of the pitot tube is located outside of the blower
Two different models were used; one for domestic ov- wheel. This means that the pressure applied to
ens, and another for export ovens. The switches are the end of the tube is positive. Because of this,
identical except for the markings on the dial. The do- the tube should be connected to the positive side
mestic unit measures pressure in water column inches of the switch.
(in. W.C.), while the export unit measures pressure in • If the switch is used to detect burner blower opera-
millibars (mbar). tion, check the type of burner used on the oven.
• Domestic switch: Kit P/N 35624 - The Midco burner, used ONLY on some
• Export switch: Kit P/N 35625. PS360EWB and PS360WB70 ovens, has its
3. Dungs square-case “alternate” air switch with threaded pitot tube mounted inside the blower wheel.
screw-type adjustment (P/N 36194) For correct operation, you should attach the
tube to the NEGATIVE side of the switch.
This switch was used on a limited number of domestic
production ovens in early 1997 to cover an availability Refer to Figure 51 for an illustration of the Midco
problem with the standard switch (see #2 above). Mark- burner.
ings were in water column inches (in. W.C.). An export - For ovens with the standard Wayne burner, the
version of this switch was never used. pitot tube is mounted outside the blower wheel.
For correct operation, you should attach the
This switch was never available as a service part. If it
tube to the POSITIVE side of the switch.
must be replaced, use Kit P/N 35624 (see #2 above).
Note that some PS360EWB and PS360WB70
4. Yamatake-Honeywell air switch, non-adjustable ovens use the Wayne burner. You should al-
This switch is the current standard for all new-produc- ways check the type of burner installed into
tion Middleby ovens. You may NOT use this switch as the oven before connecting the air tube. Refer
an upgrade on an oven equipped with an older switch. to Figure 52 for an illustration of a typical
Two different models are used; one for dometic and PS360WB70/EWB gas train with the Wayne
standard export ovens, and another for CE-approved burner.
ovens.
Figure 51 Figure 52
PS360WB70/EWB with Midco burner PS360WB70/EWB with Wayne burner
Connects to
negative pressure
side of air switch

Connects
to positive
pressure
side of air
switch

82
 SECTION 3 - SERVICING COMPONENTS

C. Appendices Appendix - Instructions for Service Kits 35624 and 35625 -

Air Pressure Switch Replacement Kits, 1/97

83
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kits 35624 and 35625 -

Air Pressure Switch Replacement Kits, 1/97

84
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions to Replace an “Alternate” Air Switch

P/N 36194 with Service Kit P/N 35624, 3/97

85
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions to Replace an “Alternate” Air Switch

P/N 36194 with Service Kit P/N 35624, 3/97

86
 SECTION 3 - SERVICING COMPONENTS
IX. PS570/570S FLAME GATE B. Flame Gate Orientation
All PS570/570S ovens produced for Pizza Hut USA through To check the position of the flame gate, view it through
8/00 were equipped with an adjustable flame gate at the the oven’s window. See Figure 53. The gate must
end of the burner tube. The purpose of the flame gate was point towards the EXIT end of the oven. Note that this
to direct heat towards the entrance end of the oven to bet- directs the flame from the burner tube towards the EN-
ter suit the customer’s cooking needs. TRANCE end of the oven, as described above.
PS570S ovens produced 9/00 or later, as well as all PS570G All ovens were originally shipped from Middleby Marshall
ovens, are not equipped with the flame gate. The introduc- with the gate pointing to the right. This is because all
tion of the modulating gas system to these ovens, as well ovens were shipped with left-to-right conveyors. If the
as improvements to the customer’s air finger configuration conveyor direction of one of these ovens is reversed in
the field, the flame gate should be repostioned as fol-
and baking specs, make the flame gate unneccessary on
lows:
these ovens.
• Loosen (do not remove) the two 7/16” hex bolts on
A. Part Number Reference - Flame Gate
the clamps that hold the adjustment rod in place.
Part No. Description • Insert a #2 Phillips-head screwdriver into the hole
35210-0555 Flame gate in the rod as shown in Figure 53. Swing the handle
35210-0511 Adjustment rod of the screwdriver to rotate the rod and move the
flame gate. You should position the gate as far as
35210-0510 Clamp possible towards the EXIT end of the conveyor as
shown.
• Remove the screwdriver. Tighten the two screws
to hold the clamps in place.
Figure 53
PS570/570S flame gate adjustment
LEFT-TO-RIGHT conveyor travel RIGHT-TO-LEFT conveyor travel
(factory setting) (factory setting)

Direction of Direction of
conveyor travel conveyor travel

Gate points to Gate points to

RIGHT (exit) LEFT (exit)
end of oven end of oven

Metal clamps
hold rod in
place

7/16” hex
bolts (2)

Rotate screwdriver
handle to reposition
flame gate
87
SECTION 3 - SERVICING COMPONENTS
X. GAS TRAIN AND BURNER SYSTEM Figure 54
A. Part Number Reference - PS200-series gas train
Gas Train Components
Air shutter
Burner blower and motor assy
42810-0087
OVENS WITH ON/OFF
OVENS WITH GAS SYSTEM ONLY:
MODULATING GAS 120V motor assy with centrifugal
SYSTEM ONLY: safety switch 27170-0011
M420 modulating OVENS WITH MODULATING
valve, 1/2” GAS SYSTEM ONLY:
41647 208/240V motor assy 27170-0287

OVENS WITH ON/OFF

GAS SYSTEM ONLY:
Junction box
Includes:
240Vp:120Vs
Combination gas transformer 27170-0017
control valve, 1/2” Relay 27170-0016
45688

OVENS WITH
ON/OFF GAS
1/2” union SYSTEM ONLY:
23051-0003 Solenoid valve, 1/2”
Pilot
pressure 28091-0017
Pilot line
Manual shutoff Bypass line (1/4” aluminum tap
valve, 1/2” (1/4” aluminum tubing) 30185
23115-0009 tubing) 15125-0002
15125-0002 (per foot)
(per foot)

Figure 55
PS310, PS314, PS360 or PS360WB gas train
Burner blower and motor assy, 120V
with centrifugal safety switch
27170-0011

Air shutter
42810-0087

Solenoid valve, 1/2”

28091-0017

Combination gas Junction box

control valve, 1/2” Includes:
45688
240Vp:120Vs
1/2” union transformer
23051-0003 27170-0017
Relay
27170-0016

Pilot line
Manual shutoff (1/4” aluminum
valve, 1/2” tubing)
Pilot
23115-0009 15125-0002
pressure
Bypass line (per foot)
tap
(1/4” aluminum tubing) 30185
15125-0002
(per foot)
88
 SECTION 3 - SERVICING COMPONENTS

Figure 56
PS360EWB or PS360WB70 gas train with Midco burner
PS360WB70 PS360WB70 ONLY: Air tube
ONLY: Solenoid valve, 3/4” (silicone rubber)
Bypass line 31500 22450-0297 Air shutter
(1/4” aluminum (per foot) 36830
tubing) TO NEGATIVE (-)
15125-0002 SIDE OF AIR
(per foot) SWITCH
PS360EWB ONLY:
M420 modulating
valve, 3/4”
32570

Burner blower
motor,
3/4” union 208/240V
23051-0004 32195

Manual shutoff
valve, 3/4”
23115-0010
Pilot
pressure
tap

Pilot orifice
Pilot line See chart on
Main orifice
Combination gas (1/4” aluminum tubing) Page 69
See chart on
control valve, 3/4” 15125-0002 Page 69
32569 (per foot)

Figure 57
PS360EWB or PS360WB70 gas train with Wayne burner
PS360WB70 ONLY:
Solenoid valve, 3/4”
31500

Air tube
(silicone rubber) Air shutter
PS360EWB ONLY:
22450-0297 42810-0087
M520 modulating
(per foot)
valve, 3/4”
TO POSITIVE (+)
32570 Burner blower
SIDE OF AIR
and motor assy,
SWITCH
Combination gas 208/240V
control valve, 3/4” 27170-0287
32569

PS360WB70 ONLY:
Bypass line
(1/4” aluminum tubing) 3/4” union
15125-0002 23051-0004
(per foot)

Manual shutoff
valve, 3/4”
23115-0010

Pilot line Pilot

(1/4” aluminum pressure
tubing) tap
15125-0002 30185
89 (per foot)
SECTION 3 - SERVICING COMPONENTS

Figure 58
PS570S gas train
Burner blower and
motor assy, 120V
OVENS RETROFITTED with centrifugal
WITH MODULATING safety switch
GAS SYSTEM ONLY: 27170-0011
M420 modulating
valve, 1/2”
41647
Flexible air hose
22450-0255

1/2” union
23051-0003
Air shutter
42810-0087

NOT SHOWN
Pilot line (components are
(1/4” aluminum tubing) installed on back wall
15125-0002 of machinery
(per foot) compartment):
Combination gas 240Vp:120Vs blower
Solenoid valve, 1/2” motor transformer
control valve, 1/2”
28091-0017 Pilot 27170-0017
45688
Manual shutoff pressure
valve, 1/2” Relay
Bypass line tap
23115-0009 27170-0016
(1/4” aluminum tubing) 30185
15125-0002
(per foot)

Figure 59
PS570G or PS555 gas train

Air shutter
42810-0087

Pilot line
M420 modulating (1/4” aluminum tubing)
valve, 1/2” 15125-0002
41647 (per foot) Burner blower
Combination gas and motor assy,
control valve, 1/2” 208/240V
45688 27170-0287

1/2” union
23051-0003

Air tube
(silicone rubber)
22450-0297
(per foot)
TO POSITIVE (+)
SIDE OF AIR
Flexible air hose SWITCH
22450-0255
Manual shutoff
valve, 1/2” Pilot pressure tap
23115-0009 30185
90
 SECTION 3 - SERVICING COMPONENTS

Figure 60 - Wayne burner - exploded view

Pilot/ignitor
assembly
42810-0117 Venturi
Pilot shield
27170-0204 Wtih angled flame target: Burner blower and motor assy
27170-0223 120V: 27170-0011
With round flame target: 208/240V: 27170-0287
38127

Air shutter
42810-0087

Pilot orifice Main orifice

See chart below See chart below

Pitot tube assembly

(for use with 208/
240V motors)
42400-0640
B. Part Number Reference - Gas Orifices and Gas Conversion Kits
PS360WB70/EWB PS360WB70/EWB
PS200 PS220/224 PS310/314/360 PS360WB Midco burner Wayne burner PS555 PS570S/PS570G Description

42810-0125 42810-0126 42810-0120 42810-0127 36863 44664 43061 42810-0127 GAS CONVERSION KIT,
PROPANE TO NATURAL

22176-0010 22176-0016 22176-0004 22176-0014 31821 22176-0014 43059 22176-0014 MAIN ORIFICE, NATURAL
0.204”/5.18mm 0.182”/4.62mm 0.219”/5.56mm 0.250”/6.35mm 0.234”/5.94mm 0.250”/6.35mm 0.228”/5.79mm 0.250”/6.35mm GAS

22174-0011 22174-0011 22174-0011 22174-0011 31818 22174-0011 22174-0011 22174-0011 PILOT ORIFICE, NATU-
0.028”/0.71mm 0.028”/0.71mm 0.028”/0.71mm 0.028”/0.71mm 0.032”/0.81mm 0.028”/0.71mm 0.028”/0.71mm 0.028”/0.71mm RAL GAS

22174-0006* 22174-0006* 22174-0006 22174-0006 22174-0006* 22174-0006* NONE* 22174-0006* BYPASS ORIFICE, NATU-
0.060”/1.52mm/ 0.060”/1.52mm/ 0.060”/1.52mm/ 0.060”/1.52mm/ 0.060”/1.52mm/ 0.060”/1.52mm/ 0.060”/1.52mm/ RAL GAS
#53 drill #53 drill #53 drill #53 drill #53 drill #53 drill #53 drill

28092-0019 28092-0019 28092-0019 28092-0019 28092-0019 28092-0019 28092-0019 28092-0019 GAS VALVE SPRING KIT,
NATURAL GAS

42810-0122 42810-0123 42810-0119 42810-0124 36856 44665 43062 42810-0124 GAS CONVERSION KIT,
NATURAL TO PROPANE

22176-0007 22176-0017 22176-0003 22176-0015 31822 31980 43060 22176-0015 MAIN ORIFICE, PROPANE
0.1285”/3.26mm 0.113”/2.87mm 0.134”/3.40mm 0.152”/3.86mm 0.185”/4.70mm 0.165”/4.19mm 0.141”/3.58mm 0.152”/3.86mm

22174-0010 22174-0010 22174-0010 22174-0010 31819 22174-0010 22174-0010 22174-0010 PILOT ORIFICE, PROPANE
0.018”/0.45mm 0.018”/0.45mm 0.018”/0.45mm 0.018”/0.45mm 0.025”/0.64mm 0.018”/0.45mm 0.018”/0.45mm 0.018”/0.45mm

22174-0009* 22174-0009* 22174-0009 22174-0009 22174-0009* 22174-0009* NONE* 22174-0009* BYPASS ORIFICE, PRO-
0.038”/0.97mm/ 0.038”/0.97mm/ 0.038”/0.97mm/ 0.038”/0.97mm/ 0.038”/0.97mm/ 0.038”/0.97mm/ 0.038”/0.97mm/ PANE
#62 drill #62 drill #62 drill #62 drill #62 drill #62 drill #62 drill

28092-0018 28092-0018 28092-0018 28092-0018 28092-0019 28092-0018 28092-0018 28092-0018 GAS VALVE SPRING KIT,
(same as PROPANE
natural gas)
* NOTE
Bypass orifices are used ONLY on ovens equipped with an on-off gas regulation system (with a solenoid valve). These ovens include:
• PS200-series • PS310 • PS360 • PS360WB70
(through 3/02) • PS314 • PS360WB • PS570S (through 8/00)
Ovens equipped with a PID modulated gas system (with a modulating valve) do not use a bypass orifice. These ovens include:
• PS200-series • PS360EWB • PS570S • PS570G
(4/02 or later) • PS555 (9/00 or later)

NOTE: Installations at higher altitudes have a lower ambient air pressure that disrupts the air-fuel mixture. To correct this
problem, smaller gas orifices are required. A general rule is a 4% reduction for each 1000 ft. (305m) above sea level. Refer
to the chart in the Appendices section (page 135) for a listing of orifice sizes showing this reduction.
91
SECTION 3 - SERVICING COMPONENTS
C. Component Identification 1. Solenoid valve vs. Modulating valve
1. Burner type Middleby ovens use one of the following systems for
Middleby ovens are equipped with one of two main burner gas flow regulation:
designs. Details of these burners are provided below. • On-Off gas flow regulation. These ovens are
1. Midco burner - see Figure 61. This burner was equipped with a high flame solenoid valve. The
used on PS360WB70 and PS360EWB ovens only. solenoid valve can only be positioned fully open
(100% gas flow) or fully closed (0% gas flow) as
Late-production PS360EWB and PS360WB70 ov- necessary to maintain the set point. A bypass line
ens used the Wayne burner shown in Figure 62. In supplies gas to maintain the flame when the valve
addition, many PS360EWB ovens were retrofitted is closed. On/off gas systems have a temperature
during 1998 to use the Wayne burner. “swing” of several degrees on either side of the set
Servicing the Midco burner is beyond the scope of point.
this manual. However, note that most gas train On-Off gas flow regulation is used on the following
components EXCEPT FOR THE BURNER ITSELF Middleby oven models:
are identical to the components used with the
Wayne burner. If necessary, contact Middleby Tech- - PS200-series - PS360WB
nical Service for assistance. (through 3/02) - PS360WB70
- PS310 - PS570S
2. Wayne burner - see Figure 62. Wayne burners are - PS314 (through 8/00)
used on all Middleby oven models except early- - PS360
production PS360WB70 and PS360EWB models.
Additional information on the solenoid valve is pro-
The Wayne burner configuration varies slightly be- vided in Solenoid Valve on Page 96.
tween oven models and so may be slightly differ-
• Modulated gas regulation. These ovens are
ent from that shown in Figure 62. Refer to the
equipped with a modulating gas valve. The modu-
drawings in Part Number Reference - Burner Com-
lating valve can open or close at any setting from 0-
ponents (pages 88-90) for illustrations of the burner
100% gas flow in response to the need for heat to
configuration used on each oven model. Common
maintain the set point. Because of this flexibility,
variants include:
the temperature “swing” is eliminated.
• Flexible air tube between the burner blower and
The modulated gas system is used on the following
plenum. Used on all PS555/570 series ovens.
Middleby oven models:
• 120V burner blower motor. Used on PS200-
- PS200-series - PS570S
series (through 3/02), PS310, PS314, PS360,
(4/02 or later) (9/00 or later)
PS360WB and PS570S ovens.
- PS360EWB - PS570G
• 208/240V line voltage blower motor. Used on - PS555
PS200-series (4/02 or later), PS360WB70, Additional information on the modulating valve is
PS360EWB, PS555, and PS570G ovens. provided in Modulating Valve on Page 97.

Figure 61 - Midco burner Figure 62 - Wayne burner

PS360EWB shown. For different oven models, refer
Burner blower
to the drawings on pages 88-90.
Air
shutter Plenum Burner Air shutter
blower

Main gas
line
Main gas Burner
line blower
motor

Plenum

Burner
Pilot line blower
Pilot line motor
92
 SECTION 3 - SERVICING COMPONENTS
D. Pilot/Ignitor Assembly Figure 63 - Pilot/ignitor assembly
The pilot assembly is attached to the end of the pilot line. Pilot line
It consists of an ignitor electrode/flame sensor, a pilot shield connects here
and the pilot burner. See Figure 63. Pilot
burner
The pilot assembly includes a safety circuit. An electrical
current is sent to the flame sensor probe to prove the pres- Hood
ence of the pilot flame. When the spark ignites the pilot, a
circuit is completed THROUGH THE FLAME from the flame
sensor probe to the pilot burner, which is grounded. This
safety circuit must be completed before the pilot will light.
1. Pilot Shield
The pilot shield is a plate located on the bottom of the
pilot. It prevents drafts, etc. from blowing the pilot flame Ignitor/sensor Spark cable
probe connects here
away from the sensing probe. See Figure 64.
2. Flame target
The flame target aids in distributing the flame from the
end of the venturi. See Figure 65.
Figure 64
• PS310/360-series ovens built prior to 6/87 are not End of burner without flame target
equipped with a flame target. The burner on these
ovens resembles the one shownin Figure 64.
showing pilot shield
• The angled flame target is used on:
- PS200-series ovens built through 3/02.
- PS310, PS314, PS360 and PS360WB ovens
built 6/87 or later.
- PS570S ovens.
All of these ovens use a 120V burner blower motor.
Most units equipped with the 120V burner blower
motor also use the angled flame target.
• The round flame target is used on:
- PS200-series ovens built 4/02 or later.
- PS360EWB and PS360WB70 ovens equipped
with the Wayne burner system.
Pilot
- PS555 and PS570G ovens. shield
All of these ovens use a 208/240V burner blower
motor. All ovens equipped with the line voltage
burner blower motor use the round flame target.

Figure 65
Flame targets

Angled Round
target target

93
SECTION 3 - SERVICING COMPONENTS
3. Pilot and Proof of Pilot Flame Figure 66 Figure 67 - Flame rectification
Rectification Flame structure
With standing pilots, heat is
a necessary ingredient for
proper thermocouple opera-
tion. But this is not the case
with IIDS (Intermittent Ignition
Device Systems) when flame
conduction or rectification is
used. To better understand the
principles of flame conduction
and rectification, we must first
understand the structure of a
gas flame. See Figure 66. Figure 68 - Pilot and probe
With the proper air-gas ratio to give a blue pilot flame,
three zones exist.
Zone 1: An inner, fuel-rich cone that will not burn be-
cause excess fuel is present.
Zone 2: Around the inner, fuel-rich cone is a blue enve-
lope. In this area is a mixture of vapor from the fuel-rich
inner cone and the secondary, or surrounding, air. This
is where combustion occurs.
Zone 3: Outside the blue envelope is a third zone that
contains an excessive quantity of air and will not burn.
Of concern is the second, or combustion area. This is
where the burning occurs and is the area that is of
prime importance for good flame sensor location.
Flame Rectification
With flame rectification, two probes with different sur-
face areas are exposed to a flame - in this case, the
pilot flame. The probe with the larger surface area at-
tracts more free electrons and, as a result, becomes
the negative probe. Therefore, current is conducted THE FOLLOWING CONDITIONS WILL HAVE A DIRECT
through the flame from the positive probe to the nega- BEARING ON EVERY IID APPLICATION:
tive probe. See Figure 67.
Voltage
Note also that the AC voltage sine wave has not
changed, but the negative portion of the current sine The supply voltage to the ignition controls should be
wave has been chopped off. This positive portion now within the following ranges:
represents a DC current. This is the phenomenon of • 120VAC controls – 102 to 132VAC
flame rectification. • 24VAC controls – 21 to 26.5VAC
To apply this principle to an IID (Intermittent Ignition 24VAC systems should use transformers that will pro-
Device - in this case, the pilot/ignitor assembly), a pilot vide adequate power under maximum load conditions.
and flame sensor have been substituted for the two Gas Pressure
probes (See Figure 68). After the pilot is ignited, a DC
Inlet gas pressures
current flow of 2.0mA (microamps) or more is conducted
• Natural gas, Wayne burner - 6-12” W.C. (14.9-29.9 mbar)
through the flame, from the flame sensor (the positive
• Propane, Wayne burner - 11½-12” W.C. (28.7-29.9 mbar)
probe) to the pilot tip (the negative probe). The pilot tip,
• Midco burner (all gases) - 6-14” W.C. (14.9-34.9 mbar)
acting as the negative probe, completes the circuit to
ground. The IID sensing circuit uses this DC current Regulated gas pressures
• Natural gas, Wayne burner - 3.5” W.C. (8.7 mbar)
flow to energize a relay and open the main burner gas
• Propane, Wayne burner - 10” W.C. (24.9 mbar)
valve.
• Midco burner (all gases) - 3-5” W.C. (7.5-12.5 mbar)
Pilot gas pressures
• Natural gas, Wayne burner - 3½-4” W.C. (8.71-9.95 mbar)
• Propane, Wayne burner - 8-10” W.C. (19.9-24.9 mbar)
• Midco burner (all gases) - 5-6” W.C. (12.5-14.9 mbar)
94
 SECTION 3 - SERVICING COMPONENTS
Temperature In these cases, the pilot may ignite, but the main burner
Ignition controls should not be exposed to tempera- gas valve will not be energized. It is also possible for
tures exceeding 140°F (60°C) or less than -40°F (-40°C). drafts or unusual air currents to deflect the pilot flame
away from the flame sensor. Deflection of the pilot
Pilot Application
flame may also be caused by main burner ignition con-
The pilot and flame sensor application is the most criti- cussion or roll-out of the main burner flame.
cal aspect of the llD application.
An additional point to be considered is the condition of
The pilot flame must make contact with the pilot tip the pilot flame. If the pilot flame is hard and blowing,
and surround the flame sensor probe. A multimeter or the grounding area of the pilot is reduced to a point
ampmeter set to read microamps (mA) is necessary to where the necessary current is not being maintained,
verify that the proper amount of current is being main- and a shutdown of the system will result.
tained through the pilot flame. The minimum value
The positioning of the flame sensor is also critical in
required is 2.0 mA. Rectification-based ignition sys-
the pilot application. Positioning of the flame sensor
tems respond in less than 0.8 of a second to a loss of
should be such that it will be in contact with the sec-
flame. If the minimum signal is not being maintained
ond, or combustion area of the pilot flame. Passing
at all times, OR if the pilot flame is briefly directed
the flame sensor through the inner cone of the pilot
away from the flame sensor or pilot tip, the main gas
flame is not a recommended procedure. For this rea-
valve may cycle rapidly (“chattering”) or the burner may
son, a short flame sensor may provide a superior sig-
be prevented from activating.
nal over a longer one. The final determination of the
Other conditions that can cause the failure of the main sensor location (length) is best determined by the use
burner to activate, OR chattering of the burner, are: of a multimeter set to read microamps (mA).
1. Pilot flame is too small.
2. Gas pressure is too low for proper pilot flame im-
pingement on the flame sensor.

E. Burner Blower Motor Figure 69

The burner blower motor is located on the side or top of the Air shutter adjustment
burner housing. Some blowers use a flexible tube to con-
nect the blower to the burner, depending on the available Wayne burner
space inside the machinery compartment. The burner Standard openings:
blower motor drives a blower wheel located in a housing • 1/4”/6.4mm for natural gas ovens
attached to the end of the motor that is the primary air • 3/8”/9.5mm for propane ovens
supply for combustion. The motor requires no lubrication. Counter-
Loosen hex
Clockwise - clockwise -
Depending on the oven model, the burner motor operates less air
nut to adjust
more air
on either 120V or 208/240V (line voltage). 120V motors shutter
have an internal centrifugal switch that controls the 24V
power supply to the gas valve (see Burner Blower Motor
Centrifugal Safety Switch on Page 80). 208/240V motors
use a separate air pressure safety switch to sense blower
operation (see Air Pressure Safety Switch on Page 81).
This safety feature prevents burner operation in case of motor
failure.
F. Air Shutter
The air shutter is a round metal plate located on the open
end of the burner blower wheel. Adjusting the position of Midco burner
the shutter will increase or decrease the amount of air that Standard opening 5/16”/7.9mm (all gases)
is permitted into the plenum for combustion. Rotate the Clockwise - Counterclockwise -
plate in a counterclockwise direction to increase the air less air Loosen more air
supply, or in a clockwise direction to reduce the air supply. screw to
adjust
You can insert a drill bit into the shutter gap to check the shutter
size of the opening. Refer to Figure 69 for the recommended
opening sizes.
Early Midco burners use an adjustment screw on the front
wall of the plenum to adjust the airflow. If it is not possible
to adjust the air supply properly using the screw, a retrofit
kit is available (P/N 36829) to install the external air shutter
shown in Figure 69. 95
SECTION 3 - SERVICING COMPONENTS
G. Burner Transformer pass line that goes around the solenoid valve. This allows
120V burner blower motors feature a transformer located in the burner to operate in low flame mode while awaiting re-
the electrical junction box on the burner. In PS570S ovens, activation.
AND all ovens with 208/240V burner blower motors, the When the oven has been fully preheated and has main-
transformer is located inside the machinery compartment. tained the set point for about an hour with a moderate prod-
The transformer supplies 24V to the burner motor relay (if uct load, the low flame to high flame ratio should be ap-
present) and also to the 24V gas valve through the motor’s proximately 1 to 1. That is, the oven will be calling for heat
centrifugal switch (or air pressure safety switch). approximately half the time. To check this ratio, refer to
the HEAT indicator on the temperature controller, which will
H. Burner Motor Relay only be active when the burner is on high flame.
120V burner blower motors feature a 24V time delay relay EXCEPTION: Older PS310/314/360 ovens have a tempera-
located in the electrical junction box on the burner. In ture-sensing thermocouple mounted at the front of the oven,
PS570S ovens, the relay is located on the back wall of the inside the machinery compartment. On these ovens, the
machinery compartment. low flame to high flame ratio should be approximately 2 or 3
Approximately 25 seconds after power is applied to the coil to 1 (oven calls for heat 1/3 or 1/4 of the time).
of the relay, the contacts will close and complete a circuit
to the burner blower, allowing the motor to operate. This IMPORTANT: For proper functioning of the sole-
15-30 second delay is a prepurge for a cold start. When noid valve, the temperature controller MUST be
the coil of the relay is warm, the delay is bypassed. set to the on-off operating mode. Refer to Tem-
Ovens with 208/240V burner blower motors are not equipped perature Controller on Page 31.
with the burner motor relay, and do not have a prepurge for
a cold start. J. Bypass (Low Flame) Orifice (ovens with a high
I. High Flame Solenoid Valve (if so equipped) flame solenoid valve only)
Ovens that use an on-off gas regulation system are equipped All ovens that use an on-off gas regulation system are
with a high flame solenoid valve. The valve is located be- equipped with an orifice in the low flame bypass line. See
tween the combination gas control valve and the burner. Figure 70.
The valve operates on 110-120V. When the oven is not calling for heat, the solenoid valve is
The valve opens when the oven’s temperature falls 2 de- closed, but gas is still supplied to the burner through the
grees Fahrenheit below the set point, and closes when the bypass line. This allows the burner to operate in low flame
temperature rises to 2 degrees above the set point. Be- mode while awaiting re-activation.
cause of residual heat within the oven, however, the tem- The low flame orifice regulates the gas flow through the
perature swing after preheating is about 5 degrees Fahren- bypass line. If the orifice size is too large, the low flame
heit above and below the set point. will be too high. In some cases, this will prevent the oven
The solenoid valve can only be positioned fully open (100% from being able to maintain the set point.
gas flow) or fully closed (0% gas flow). While the valve is Refer to the chart on Page 91 to determine the proper size
closed, gas is still supplied to the burner through the by- for the bypass orifice.

Figure 70
Low Flame (Bypass) Orifice
Bypass line configuration varies depending on the oven model. Refer to the drawings on pages 88-90.

Low flame Solenoid

(bypass) valve
orifice

Bypass
line

96
 SECTION 3 - SERVICING COMPONENTS
K. Modulating Gas Valve (if so equipped) The modulating valve features a bypass adjustment screw,
Ovens that use a PID (modulated) gas regulation system shown in Figure 71. For all ovens except the PS536, the
are equipped with a modulating gas valve instead of a sole- screw should ALWAYS remain fully closed; no adjustment
noid valve. The valve is located between the combination is necessary. The screw is pre-set to the fully-closed posi-
gas control valve and the burner. tion from the factory. If the screw is adjusted to any setting
other than fully-closed, the oven may not be able to main-
In response to the millivolt signal from the thermocouple, tain the set point temperature.
the Digital Temperature Controller sends a 4-20mA signal
to an amplifer board. The board, in turn, passes on a 0-
IMPORTANT: For proper functioning of the modu-
20VDC signal to the modulating valve itself. The valve opens
lating valve, the temperature controller MUST be
or closes proportionally to the signal from the amplifier board,
set to the PID operating mode. Refer to Tempera-
allowing any setting from 0-100% gas flow.
ture Controller on Page 31.
When the oven is switched on, gas demand is at its peak
and the valve is fully open, permitting 100% gas flow. As
the oven’s temperature approaches the set point, the valve
slowly begins to close, restricting gas flow to the 35-60%
range. After the oven is fully preheated, the gas flow usu- L. Amplifier Board (ovens with a modulating gas
ally stabilizes at about 30%. The actual oven temperature valve only)
can remain constant, with NO temperature swing, because Ovens equipped with a modulating gas valve have an ampli-
the valve is adjusted constantly according to the demand. fier board mounted inside the machinery compartment.
Modulating valves are used on all PS360EWB, PS555, and In response to the millivolt signal from the thermocouple,
PS570G gas ovens. They are also used on PS200 ovens the Digital Temperature Controller sends a 4-20mA signal
produced 4/02 or later and PS570S ovens produced 9/00 or to the amplifer board. The board, in turn, passes on a 0-
later. 20VDC signal to the modulating valve. The valve opens or
The Model PS360EWB oven uses a Maxitrol M520 modu- closes proportionally to the signal from the amplifier board,
lating valve with a 3/4” gas line, P/N 32570. All other allowing any setting from 0-100% gas flow.
Middleby oven models equipped with a modulating valve All Middleby oven models equipped with a modulating valve
use the Maxitrol M420 valve with a 1/2” gas line, P/N 41647. use amplifier board P/N 31651.

Figure 71 - Modulating Gas System

Digital Temperature
To transformer Controller
MUST BE SET TO PID
24VAC input
OPERATING MODE
orange/white orange
white +
blue To thermocouple
red -
blue/white

purple/white
bypass adjustment purple
screw (under cap)
MUST BE FULLY
CLOSED Amplifier Board
Modulating Valve

To amplifier board terminal 6

purple PS360EWB
with Controller 32571
To amplifier board terminal 5 purple/white only

97
SECTION 3 - SERVICING COMPONENTS
M. Combination Gas Control Valve 3. Servicing the Combination Valve
1. Part Number Reference - Combination Gas Valve • Pilot pressure
• PS360WB70 and PS360EWB ovens are equipped with One of the more common service issues with the com-
a 3/4” (19.05mm) gas line. This requires the use of bination valve occurs on ovens with the on/off gas regu-
Combination Gas Valve P/N 32569. The valve has a lating system (with a solenoid valve), when the oven is
tan plastic cover with a blue On/Off knob. on low flame. During low flame, the servo can “bounce”
inside the valve as it searches for the proper level. The
• All other oven models are equipped with a 1/2” (12.7mm) bouncing line pressure can also cause surges in the
gas line. pilot pressure. A properly adjusted pilot will tend to
- Through 10/01 - these ovens used Valve P/N 28092- smooth out the surges.
0017. The valve operated on a 60 Hz supply, had a The best way to check for a properly adjusted pilot is
tan plastic cover and a blue On/Off knob. to check the pilot line pressure. This requires a pilot
- 11/01 and later - these ovens use Valve P/N 45688. pressure tap in the pilot line. Ovens built 3/94 or later
The valve operates on a 50 or 60 Hz supply, has a should have the tap installed in the line. The tap is
grey plastic cover and a black On/Off knob. It is also available as Service Kit P/N 30185 which includes
otherwise identical to the previous version, and may installation instructions.
be used to replace it in all cases. Recommended pilot gas pressures are:
2. Valve Operation - Wayne burner, natural gas - 3½-4” W.C. (8.71-9.95
When the ON-OFF knob on the valve is in the ON position, mbar)
gas is allowed to enter the valve. Once 24VAC is supplied - Wayne burner, propane - 8-10” W.C. (19.9-24.9
to the valve, gas is supplied to the pilot line. mbar)
- Midco burner (all gases) - 5-6” W.C. (12.5-14.9
When the pilot flame has been proved (see Pilot and Proof
mbar)
of Flame Rectification on Page 94), 24VAC is supplied to
the combination valve by the ignition module, opening the • Burrs in pilot adjustment portal
main valve. Gas pressure from the inlet side of the valve is Some combination valves have been shown to have
passed through the Pressure Regulator. The regulated pres- shipped with small burrs in the pilot adjustment portal.
sure is supplied to a cavity below the main valve diaphragm. Although this will not interfere with proper operation of
This pressure overcomes the spring force and moves the the valve in any way, it does make it difficult to adjust
main valve to its open position. During operation, the main the pilot pressure until the burr is removed.
valve is opened and closed by the pressure regulator to Check for a burr by attaching a manometer to the pilot
keep a constant pressure at the outlet of the valve. pressure tap. If the manometer does not detect any
change in pilot pressure when the screw is tightened
When power to the valve is cut, the cavity below the main
all the way down, there is probably a burr in the portal.
valve diaphragm is depressurized and the valve spring closes
the main valve rapidly to shut off the main burner. To remove a burr, perform the following procedure:
- Turn the adjustment screw all the way down.
When the 24VAC supply to the valve is cut, the valve stops
gas flow to both the pilot and the main burner. - Apply more pressure to break through the burr.
- Back the screw out until the top of the screw is
The combination valve includes taps to measure both the
level with the top of the access hole.
inlet pressure and the regulated pressure. To ensure accu-
- Turn the adjustment screw back down to adjust
racy, the regulated pressure should be measured when the
the pressure.
oven is on low flame.
- Repeat these steps until the burr is cleared.

Figure 72 - Combination Gas Control Valve

Pressure
regulator
adjustment Regulated
(under cap pressure
screw) tap

Inlet Pilot line

pressure connection
tap

Pilot pressure
On/Off knob (should adjustment (under
remain in ON position) cap screw)
98
 SECTION 3 - SERVICING COMPONENTS
N. Ignition Module If you are replacing the obsolete module (P/N 27161-
1. Part Number Reference - Ignition Module 0004) with the current version (P/N 27161-0005), BE
SURE TO DISCONNECT THE MODULE FROM THE
• PS360WB70 and PS360EWB ovens equipped with the COMMON GROUND WITH THE TRANSFORMER AND
Midco burner use Ignition Module P/N 31501. RELAY. Double-grounding of the module creates a feed-
• For all other oven models: back voltage circuit that allows the module to operate
- Through 10/90 - these ovens used Ignition Module without a signal from the burner/blower assembly. This
P/N 27161-0004. Some versions of this module procedure is explained in greater detail in the instruc-
included a separate, replaceable fuse. This mod- tions for Kit 42810-0114, included in the Appendices
ule shared a common ground with the 24V trans- section.
former and the relay coil. See Figure 73. 2. Module Operation
- 11/90 or later - these ovens use Ignition Module The ignition module delivers 24V to the pilot ignitor when
P/N 27161-0005, included in Service Kit 42810- the blower motor centrifugal switch (or air pressure safety
0114. The module is internally grounded and the switch) is closed.
common ground with the transformer and relay coil When the module detects a current flow of at least 2.0 mA
has been eliminated. See Figure 74. through the pilot flame, it supplies 24V to the combination
gas control valve, allowing the valve to operate.

Figure 73
Wiring diagram of ignition and gas valve system (obsolete ignition module 27161-0004)

Figure 74
Wiring diagram of ignition and gas valve system (current ignition module 27161-0005)

99
SECTION 3 - SERVICING COMPONENTS
O. Gas Conversion Kits P. Burner and Gas Train Troubleshooting
Ovens can be converted from natural gas to propane opera- 1. Burner Blower Motor
tion, or from propane to natural gas operation, by the instal- If there is 110V (or 208/240V, as appropriate) to the
lation of the appropriate Gas Conversion Kit. Refer to Part motor terminals, it should be running. If the motor is
Number Reference - Gas Orifices and Gas Conversion Kits not running, replace it.
on Page 91 for a listing of kit part numbers.
2. Burner Blower Motor Centrifugal Switch (or air pressure
Converting the oven to operate on a different gas type gen- safety switch)
erally requires:
If the burner blower motor is running at top speed, and
• Replacement of the regulator spring on the combina- you cannot measure 24V across the supply terminals
tion gas control valve. The spring is located under- of the ignition module, the centrifugal switch is not clos-
neath the pressure regulator screw. Note that on ing properly and is either loose or defective.
PS360EWB and PS360WB70 ovens equipped with the
Midco burner, replacement of the regulator spring is For 120V burner blower motors with an internal cen-
not necessary. trifugal switch, tighten the switch. If this fails to correct
the problem, replace the motor.
• Replacement of the main orifice, pilot orifice, and by-
pass orifice.Note that ovens equipped with the modu- For 208/240V burner blower motors with a separate air
lating gas system do not use a bypass orifice. pressure safety switch, refer to Air Pressure Safety
Switch on Page 82 to troubleshoot the switch.
• Adjustment of the main and pilot gas pressures.
3. Relay
• Documenting the gas conversion using the labels and
tags supplied in the kit. • Connect a voltmeter across the supply terminals on
the relay. The reading should be 24V. If you do not get
Instructions for the gas conversion kits are provided in the a 24V reading, the transformer should be replaced.
Appendices section.
• lf 24V is present at the relay, and if after 15 to 45 sec-
onds you do not get 110V (or 208/240V, as appropri-
ate) on terminal 3 of the relay, replace the relay.
4. Main Gas Valve and Ignition Module
If 24V can be measured across the ignition module
supply terminals, there should also be 24V between
terminals PV and MV/PV on the gas control module.
If you have a 24V reading, the pilot valve should be
open and the spark should be on to ignite the pilot gas.
When the pilot gas has ignited, the main burner should
ignite. If not, check MV terminal to ground and see if
24V is present. If no voltage is present, replace the
ignition module.
It is possible to have a pilot on, but have the spark
continue to try to light the pilot. If this continues for
more than 30 seconds, then it should be assumed that
the flame sensor is not working properly. This can be
easily checked. Refer to Control Module Flame Sensor
Test on the next page.
A reading of 2.0 mA or greater should be obtained. If a
poor reading is obtained, the pilot flame and sensor are
probably not making good contact. This will keep the
main valve from opening. Refer to the section on flame
rectification. If the microamp reading is good and 24V
cannot be obtained at terminal MV then the ignition
module should be replaced.

100
 SECTION 3 - SERVICING COMPONENTS
5. Burner Operation b. Restart the system and read the meter. The flame
a. Shut off the manual gas valve for oven. Turn the sensor current must be at least 2.0 mA, and the
Burner and Heat switches ON. The spark should reading must be steady. If the reading is below 2.0
begin at the pilot burner within 30 seconds. mA or if the reading is unsteady, check the pilot
flame and electrical connections as described
With the manual gas valve turned off, no gas will be above. Also, replace the ignitor/sensor if the ce-
present; so, the spark will continue for the lockout ramic insulator is cracked.
timing period of 90 seconds.
If the reading still is unsteady, it may be necessary
b. Turn the Heat switch OFF, then turn on the gas to adjust the pilot pressure. Refer to Pilot Pres-
supply. Set the temperature controller set point sure under Servicing the Combination Valve on Page
above the actual oven temperature. 98.
c. Turn the Heat switch ON. The system should start 8. System Troubleshooting.
as follows:
Start the system by setting the temperature controller
• Spark turns on and pilot gas valve opens at above room temperature, and observe the system re-
once. Pilot burner ignites after gas reaches sponse.
the pilot burner.
Establish the type of system malfunction or deviation
• Spark cuts off when pilot flame is established. from normal operation by using the Intermittent Pilot
• Main gas valve opens and main burner lights System Troubleshooting Table on Page 103.
after gas reaches the burner ports. Use the table by following the questions in the boxes.
NOTE: Main burner flame may not be satisfactory until If the condition is true (answers yes), go down to the
the gas input and combustion air have been adjusted. next box. If the condition is not true (answers no), go
6. Check Grounding to the box alongside.
Electrical ground connections must be clean and tight. Continue checking and answering conditions in each
If the lead wire is damaged or deteriorated, use only box until a problem and/or the repair is explained. Use
No. 14 to 18 gauge, moisture-resistant thermoplastic the Component Checks section as necessary to per-
insulated wire with a 221°F (105°C) minimum rating as form system checks.
a replacement. After any maintenance or repair, the troubleshooting
Excessive temperature at the ceramic flame rod insu- sequence should be repeated until the procedure ends
lator can also permit electrical leakage to ground. with normal system operation.
Examine the flame rod and mounting bracket, and cor-
rect if it is bent out of position. Replace the ignitor/
sensor if the insulator is cracked.
7. Ignition Module Flame Sensor Circuit Test Figure 75
The ignition module provides AC power to the ignitor/ Voltage Checks for Ignition Module and
sensor which the pilot burner flame rectifies to direct Combination Gas Valve
current (DC). If the flame signal back to the control
Ignition Module
module is not at least 2.0 mA DC, the system will lock
out. Voltage
The output of the flame sensing circuit cannot be Test Points Marked Fused Nonfused
checked directly, so check the flame sensing circuit MV/PV to PV 3 VAC 24 VAC
indirectly by checking the flame sensing current form MV/PV to MV 12 VAC 24 VAC
the ignitor/sensor to the control module as follows.
a. Connect a ampmeter or multimeter set to read DC Combination Gas Valve
microamps (mA) in series with the flame signal TR to TH 12 VAC 24 VAC
ground wire. Disconnect the ground wire at the
TH/TR to TR 3 VAC 24 VAC
control module. Connect the red (positive) lead of
the meter to the free end of the ground wire. Con-
NOTE: Information on the fused ignition module is provided
nect the black (negative) meter lead to the ground
for reference only. All ovens produced 1988 or later use the
terminal on the ignition module.
nonfused module. The fused module is no longer available.

101
SECTION 3 - SERVICING COMPONENTS
9. Component Checks Reset System After Lockout c. Check the connections to the ignitor and ignition
If the oven enters safety lockout, the system must be module terminals. All connections must be clean
reset before attempting further operation or checkout. and tight. Loose connections may not conduct a
The system will remain in safety lockout until it is re- flame current even though the ignition spark is sat-
set. Shut system OFF. (Turn Heat switch OFF.) Wait isfactory. Check the electrical continuity of the
at least five minutes, then turn Heat switch ON. cable. Replace the cable if it is damaged or dete-
riorated.
10. Check Spark Ignition Circuit
d. If no spark or a weak spark occurs, but the spark
The electronic module and step-up transformer in the ignition circuit checked normally, disconnect the
ignition module provide spark ignition at 15,000V (open ignition cable at the ignitor/sensor and measure
circuit). This circuit can be checked at the ignition the arc from the cable end to the ignitor stud. Fol-
module as follows: low the same general procedures and observe the
a. Turn OFF the gas flow at the manual shutoff valve. same cautions as in Step 10, Check Spark Igni-
b. Disconnect the ignition cable at the ignition mod- tion Circuit, above.
ule terminal to isolate the circuit from the pilot If the arc is correct, replace the ignitor/sensor.
burner/ignitor sensor, and prepare a short jumper If the arc is less than it should be, disconnect the igni-
lead using heavily insulated wire, such as a spare tion cable and use a jumper wire from the ignition mod-
ignition cable. ule stud terminal. If the spark is normal, replace the
c. Energize the ignition module and touch one end of ignition cable. If the arc is still smaller than normal,
the jumper firmly to the control board ground termi- replace the ignition module.
nal (GND). Do not disconnect the existing ground Q. Checking the Gas Pressures
lead. Move the free end slowly toward the stud
terminal to establish a spark and then pull the lead All gas pressures should be checked using a manometer
wire slowly away from the stud. Note the length of at the supplied pressure taps, as follows:
the gap at which arcing stops. • Inlet pressure can be checked at the inlet pressure tap
d. An arc length of 1/8” (3.2mm) or more indicates on the combination gas valve. See Figure 72 (on Page
satisfactory voltage output. Replace the ignition 98).
module if no arc can be established or if the maxi- • Regulated pressure can be checked at the outlet pres-
mum gap is less than 1/8” (3.2mm), and power to sure tap on the combination gas valve. See Figure 72
the ignition module input terminals was correct. (on Page 98).
WARNING Current PS555/570-series ovens provide an additional
regulated pressure tap in the main gas line, just before
Do Not touch either stripped end of jumper or stud
the line enters the burner. This allows you to connect
terminal. This is a very high voltage circuit and
a SECOND manometer downstream of the modulating
electrical shock can result. Perform the test im-
valve to check that the valve is functioning properly.
mediately upon energizing the system, before the
We encourage you to use this tap to diagnose prob-
ignition module enters safety lockout and inter-
lems with the modulating valve whenever possible.
rupts the spark circuit.
• Pilot gas pressure can be checked at the pilot pres-
11. Check Spark Ignitor
sure tap. For ovens with a Wayne burner, the tap is
If the troubleshooting procedure indicates a problem located on the pilot line. For PS360EWB/WB70 ovens
with the ignitor/sensor, check the spark ignitor and the with a Midco burner, the tap is located on the end of
ignition cable connections and continuity as follows: the pilot orifice fitting. Refer to the illustrations on Pages
Check Ignitor/Sensor 88-90.
a. Check the ignitor spark gap to make certain it is Some older ovens (pre-1994) with Wayne burners may
correct, 1/8” (3.2mm). If necessary, use a not be equipped with a pilot pressure tap. If you en-
needlenose pliers and carefully bend the tip of the counter problems with an erratic pilot (see Servicing
outer electrode to the correct gap. the Combination Valve on Page 98), it may be neces-
b. Check that the pilot flame is properly adjusted. sary to install a tap. Middleby offers Service Kit P/N
30185 which includes the pilot pressure tap and in-
Check Igniton Cable structions. A copy of the instructions are also provided
a. The ignition cable must not touch metal surfaces in the Appendices section.
or current-carrying wires. Use ceramic standoff IMPORTANT: Any older oven that has a pilot pressure
insulators, if necessary. tap installed should have the combination gas valve re-
b. Check the length of the ignition cable. It must not placed with a current version at the same time. Com-
exceed 3 ft. (0.9 m). bination valves used prior to 1994 are beyond the scope
of this Manual and may not be compatible with the tap.
102
 SECTION 3 - SERVICING COMPONENTS
R. Troubleshooting Flowcharts

103
SECTION 3 - SERVICING COMPONENTS

104
 SECTION 3 - SERVICING COMPONENTS

105
SECTION 3 - SERVICING COMPONENTS

106
 SECTION 3 - SERVICING COMPONENTS

S. Appendices Appendix - Instructions for Service Kit 42810-0117 -

Pilot/Ignitor Kit, 7/91

107
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94

108
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94

109
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94

110
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 30185 - Pilot Tee, 3/94

111
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 42810-0121 -

Combination Gas Valve, 1/92

112
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 42810-0121 -

Combination Gas Valve, 1/92

113
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 42810-0121 -

Combination Gas Valve, 1/92

114
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 42810-0121 -

Combination Gas Valve, 1/92

115
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 42810-0114 -

Ignition Module, 11/90

116
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 42810-0114 -

Ignition Module, 11/90

117
SECTION 3 - SERVICING COMPONENTS

Appendix - Position of Combination Gas Valve Components

during Burner Operation, 4/02

118
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for All Gas Conversion Kits

for Ovens with Wayne Burner, Natural Gas to Propane, 8/00

Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • USA • (847) 741-3300 • FAX (847) 741-4406

Instructions for Service Kits 42810-0119, 42810-0122, 42810-0123, 42810-0124, 43062, 44665
Gas Conversion Kit for Middleby Marshall Ovens
Natural Gas to Propane Operation
KIT COMPONENTS:
Qty. PS200 PS220/224 PS310/360 PS360WB PS360WB70/EWB PS555 PS570S Description

1 42810-0122 42810-0123 42810-0119 42810-0124 44665 43062 42810-0124 KIT, GAS CONVERSION, NATURAL

ENGLISH - page 1
TO PROPANE
1 22176-0007 22176-0017 22176-0003 22176-0015 31980 43060 22176-0015 ORIFICE, MAIN
0.1285”/3.26mm 0.113”/2.87mm 0.134”/3.40mm 0.152”/3.86mm 0.165”/4.19mm 0.141”/3.58mm 0.152”/3.86mm
1 < - - - - - - - - - - - - - - - - - - - - - - - - 22174-0010 - - - - - - - - - - - - - - - - - - - - - - - - > ORIFICE, PILOT
0.018”/0.45mm
1 22174-0009 22174-0009 22174-0009 22174-0009 22174-0009 * NONE * 22174-0009 * ORIFICE, BYPASS (HIGH-FLAME)
0.038”/0.97mm/ 0.038”/0.97mm/ 0.038”/0.97mm/ 0.038”/0.97mm/ 0.038”/0.97mm/ 0.038”/0.97mm/
#62 drill #62 drill #62 drill #62 drill #62 drill #62 drill
1 < - - - - - - - - - - - - - - - - - - - - - - - - 28092-0018 - - - - - - - - - - - - - - - - - - - - - - - - > KIT, GAS CONTROL VALVE SPRING
- PROPANE
1 < - - - - - - - - - - - - - - - - - - - - - - - - 22500-0065 - - - - - - - - - - - - - - - - - - - - - - - - > LABEL, PROPANE (RED)
1 < - - - - - - - - - - - - - - - - - - - - - - - - 22500-0123 - - - - - - - - - - - - - - - - - - - - - - - - > LABEL, GAS CONVERSION
1 < - - - - - - - - - - - - - - - - - - - - - - - - 22501-0007 - - - - - - - - - - - - - - - - - - - - - - - - > TAG, GAS CONTROL CONVERSION
1 < - - - - - - - - - - - - - - - - - - - - - - - - 88210-0069 - - - - - - - - - - - - - - - - - - - - - - - - > INSTRUCTIONS

ESPAÑOL - página 7
* NOTE: The bypass orifice is not used if the oven is equipped with a modulating gas valve. These ovens include:
• PS360EWB (all)
• PS555 (all)
• PS570S (units produced 4/00 or later)
For additional information, refer to Part III of these instructions (Bypass Orifice Conversion).

IMPORTANT
THIS CONVERSION KIT IS INTENDED FOR AGA-, CGA-, AND CSA-APPROVED MIDDLEBY
MARSHALL GAS-FIRED OVENS OPERATING AT ALTITUDES UP TO 5000 FT. (1524m).
FOR OVENS INSTALLED AT ALTITUDES ABOVE 5000 FT. (1524m), CONSULT THE FAC-
TORY BEFORE INSTALLING THIS KIT.
THIS KIT MAY NOT BE USED WITH CE-APPROVED MIDDLEBY MARSHALL OVENS.
FOR THESE OVENS, FOLLOW THE GAS CONVERSION INSTRUCTIONS IN THE INSTAL-
LATION SECTION OF THE OVEN’S OWNER’S OPERATING AND INSTALLATION MANUAL.

WARNING
THIS CONVERSION KIT IS TO BE INSTALLED BY A MIDDLEBY MARSHALL AUTHORIZED SERVICE AGENT
IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS AND ALL CODES AND REQUIREMENTS
OF THE AUTHORITY HAVING JURISDICTION. FAILURE TO FOLLOW INSTRUCTIONS COULD RESULT IN
SERIOUS INJURY OR PROPERTY DAMAGE. THE AUTHORIZED SERVICE AGENT PERFORMING THIS
WORK ASSUMES RESPONSIBILITY FOR THIS CONVERSION.

WARNING
BEFORE PERFORMING ANY SERVICE WORK, THE ELECTRICAL POWER SUPPLY AND THE GAS SUP-
PLY MUST BE TURNED OFF.

1 P/N 88210-0069 • Rev. C • V1 • 8/00

119
SECTION 3 - SERVICING COMPONENTS

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
ENGLISH

Bypass Pilot pressure

line tap (pilot tee)

Gas pipe union

Typical PS300-series gas train configuration

Burner Modulating gas

blower valve (if so
equipped)

Solenoid valve
(if so equipped)
Combination gas
control valve
(safety regulator) Bypass
line Burner
Gas pipe
union
Pilot line

Manual
shutoff valve Pilot pressure tap (pilot tee)

Typical PS555 or PS570S gas train configuration

Modulating gas
Burner valve (if so
Burner blower equipped)
Solenoid valve
(if so equipped)
Combination gas
control valve
(safety regulator) Bypass
line

Pilot
line
Pilot pressure
Manual Gas pipe tap (pilot tee)
shutoff valve union
2

120
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for All Gas Conversion Kits

for Ovens with Wayne Burner, Natural Gas to Propane, 8/00
I. PREPARATION AND DISASSEMBLY Figure 1
1. Turn off the electric power supply to the oven.
2. Turn off the gas supply at the service valve behind the
oven.
3. Open the machinery compartment door. Hex
screws
4. Open the union in the gas supply line. The union is
located on the inlet side of the combination gas control
valve. See Figure 1. Gas pipe
union
5. Unscrew the four hex screws that hold the venturi
mounting plate to the front of the burner. Remove the
gas train/venturi assembly from the oven.

ENGLISH
II. COMBINATION GAS CONTROL VALVE (SAFETY
REGULATOR) CONVERSION PS570S gas train (with solenoid valve) shown.
Refer to the illustrations on Page 2 for
1. Remove and discard the following components from the component placement for other oven models.
combination gas control valve, as shown in Figure 2:
• Regulator cap screw
• Regulator adjustment screw
• Regulator spring
Figure 2
2. Install the red kit-supplied regulator spring, with the
tapered end facing into the valve, as shown in Figure 2.
3. Install the white kit-supplied regulator adjustment screw.
Carefully adjust the screw until its top is flush with the
top of the regulator.
4. Turn the adjustment screw six complete turns in a
clockwise direction. This preliminary pressure setting
is approximately 10-1/2” W.C. (26.1mbar).
Adjustment
5. Install the black kit-supplied cap screw. screw

III. BYPASS ORIFICE CONVERSION

NOTE: Ovens are equipped with EITHER an on-off solenoid Regulator
spring
valve with a separate bypass line, OR with a modulating gas
valve. Refer to the illustrations on Page 2. When installing
this Kit, the bypass orifice will only be changed if the oven
is equipped with a solenoid valve. Cap screw
• If the oven is equipped with a modulating gas valve, skip
ahead to Section IV, Pilot Orifice Conversion.
• If the oven is equipped with a solenoid valve, continue on
to Step 1, below.
Figure 3
1. Unscrew the compression nuts at both ends of the
bypass tube, and slide them back and out of the way. Compression
Then, remove and retain the tubing. See Figure 3. nut
2. Remove and discard the existing bypass orifice.
3. Slip the kit-supplied bypass orifice into the discharge
end of the bypass tube, as shown in Figure 3.
4. With the orifice in place, push the tube back into the Bypass
compression fittings until it bottoms. orifice

5. While holding the tube in place, slide the compression

nuts into place. Tighten them to a snug fit with your
fingers.
Bypass
6. Gently tighten the nuts one complete turn with a tube
wrench. DO NOT OVERTIGHTEN THE COMPRESSION
NUTS.
3

121
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for All Gas Conversion Kits

for Ovens with Wayne Burner, Natural Gas to Propane, 8/00
IV. PILOT ORIFICE CONVERSION Figure 4
1. Unscrew the two 1/2" nuts that secure the gas train to
Venturi
the venturi mounting plate. See Figure 4.
2. Unscrew the pilot tube compression nut, and slide it out Spark
of the way. Then, pull the tube from the fitting to expose cable
the pilot orifice. See Figure 4.
3. Separate the venturi, mounting plate, and gas train
assembly. Leave the main orifice holder attached to the
gas train piping assembly.
4. Remove and discard the existing pilot orifice. Pilot
orifice
5. Slip the kit-supplied pilot orifice into the pilot tube.
6. With the orifice in place, push the tube back into the
ENGLISH

compression fitting until it bottoms.

7. While holding the tube in place, slide the compression Compression
nut into place. Tighten the nut to a snug fit with your nut
fingers. Orifice
holder
8. Gently tighten the nut one complete turn with a wrench.
DO NOT OVERTIGHTEN THE COMPRESSION NUT.
9. To allow the main orifice to be replaced, do not reassemble Main
orifice
the gas train to the venturi and mounting plate at this
time.

V. MAIN ORIFICE CONVERSION

1. Unscrew the existing main orifice from its holder using 1/2” hex nuts
an 11/16” wrench. See Figure 4.
2. Install the kit-supplied main orifice into the holder.

VI. REASSEMBLY
1. Check that the pilot assembly is correctly aligned with
the venturi, as shown in Figure 5. If necessary,
reposition the pilot assembly.
2. Reassemble the venturi and mounting plate to the gas
train assembly. Replace the two 1/2” hex nuts to hold
the assembly together.
3. Replace the assembled gas train into the oven. Tighten
the gas pipe union (on the inlet side of the combination
gas valve) to hold the gas train in place.

Figure 5
View from side of venturi View from rear of venturi

Rear edge
of pilot
hood is on
centerline
of venturi

Pilot hood

3/8” (9.5mm) 11/16” (17.5mm)

122
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for All Gas Conversion Kits

for Ovens with Wayne Burner, Natural Gas to Propane, 8/00
VII. GAS LEAK TEST VIII. INLET PRESSURE CHECK
1. Restore the electrical and gas utility connections to the 1. Using a manometer, check the inlet pressure at the inlet
oven. pressure tap. See Figure 6. An inlet pressure of 11-14”
2. Paint all gas pipe connections from the union to the W.C. (27.4-34.9mbar) is recommended for propane
venturi mounting plate, as well as the pilot tubing, operation.
bypass tubing, and pressure tap plug, with a rich 2. If the inlet pressure is:
solution of soap and water (2/3 soap, 1/3 water is • HIGHER THAN 14” W.C. (34.9mbar) - This pressure
recommended). Any visible bubbles indicate a gas may damage the combination gas control valve
leak. (safety regulator). The gas supply pressure should
3. If a gas leak is detected, tighten the affected joints and be decreased.
connections. If tightening the connection(s) fails to stop • LOWER THAN 11” W.C. (27.4mbar) - It may be
the leak: necessary to increase the supplied gas pressure.
• Turn off the electric power supply to the oven.

ENGLISH
• Turn off the gas supply at the service valve behind CAUTION
the oven. IF IT IS NECESSARY TO ADJUST THE GAS LINE
PRESSURE, HAVE THE CUSTOMER CONTACT THE
• Replace the affected component(s).
GAS UTILITY SUPPLIER.
• Repeat the gas leak test.
WARNING - FIRE/EXPLOSION HAZARD
HIDDEN GAS LEAKS CAN CAUSE A FLASHBACK IX. PILOT PRESSURE ADJUSTMENT
IN THE MACHINERY COMPARTMENT. THIS
CAN CAUSE SEVERE INJURY OR DEATH. 1. Unscrew the cap plug from the pilot pressure tap (pilot
STAND WELL CLEAR WHEN SWITCHING ON tee), and attach a manometer to the tap. See Figure 6.
THE HEATING CIRCUIT. 2. Remove the pilot adjustment cap screw from the
4. If no leaks are detected by the test, depress the safety combination gas control valve.
switch(es) and switch on the oven. Then, switch on the 3. Turn the oven on, and allow it to heat to temperature.
heating circuit to ignite the burner. Make a note of the customer’s set point temperature.
5. With the burner in operation, paint all gas pipe joints with 4. After the oven has heated, adjust the set point of the
the solution of soap and water. oven far lower than its current (operating) temperature.
6. If any further gas leaks are detected, shut down the This ensures that the pilot flame will be at its lowest level
oven. Reseal and tighten the affected joints and for some time.
Continued...
connections. If tightening the connection(s) fails to stop
the leak:
• Turn off the electric power supply to the oven.
• Turn off the gas supply at the service valve behind
the oven.
• Replace the affected component(s).
• Repeat the gas leak test.
Figure 6
Adjust manifold
pressure here
(under cap screw)

Measure
Measure inlet
manifold
pressure here
pressure here

Measure pilot
pressure here
(under cap plug) Adjust pilot
pressure here
(under cap screw)
5

123
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for All Gas Conversion Kits

for Ovens with Wayne Burner, Natural Gas to Propane, 8/00
5. The pilot pressure should be adjusted as follows: X. MANIFOLD PRESSURE ADJUSTMENT
• The current flow between the pilot hood and the 1. Remove the regulator cap screw from the combination
flame sensor, when measured with a microamp gas control valve.
meter or multimeter, holds constant at a minimum 2. Using a manometer, check the pressure at the manifold
of 2.0 µA. See Figure 7. pressure tap, as shown in Figure 6. A manifold pressure
• The pilot pressure as shown on the manometer is in of 10” W.C. (24.9mbar) is recommended for propane
the range of 8-10” W.C. (19.9-24.9mbar). operation.
Adjust the pilot pressure as necessary by turning the 3. Adjust the pressure as necessary by turning the
pilot adjustment screw on the combination gas control adjustment screw on the combination gas control valve.
valve. Turning the screw clockwise decreases the pilot Turning the screw clockwise decreases the pressure.
pressure (and current flow). Turning the screw counter- Turning the screw counter-clockwise increases the
ENGLISH - page 1

clockwise increases the pressure (and current flow). pressure.

Some valves may have a burr in the pilot adjustment If the manifold pressure cannot be properly adjusted,
portal. If you have fully tightened the adjustment screw, switch the oven off and allow it to cool; then, replace the
and the manometer still does not register a change in combination gas control valve. Repeat Section VII (Gas
pressure, continue to tighten the screw to break through Leak Test) before attempting to adjust the manifold
the burr. Back the screw out until its top is flush with the pressure again.
top of its hole, then tighten the screw again as necessary 4. After the manifold pressure has been properly adjusted,
to adjust the pressure. Repeat this procedure as replace the cap screw. Record the final value on the Gas
necessary to properly adjust the pilot pressure. Conversion Label, as shown in Figure 8.
If the pilot pressure cannot be properly adjusted, switch 5. Switch the oven off, and allow it to cool.
the oven off and allow it to cool; then, replace the
combination gas control valve. Repeat Section VII (Gas XI. MARKING AND LABELING
Leak Test) before attempting to adjust the pilot pressure
1. Print the word “PROPANE” in the space provided on the
ESPAÑOL - página 7

again.
Gas Control Conversion Tag, P/N 22501-0007. See
6. After the pilot pressure has been properly adjusted, Figure 8. Fasten the tag onto the gas piping next to the
replace the cap screw. combination gas control valve.
7. Reset the oven’s set point temperature to the customer’s 2. Locate the round “NAT” label (green or yellow) on the
original settings. Leave the oven in operation to allow burner or burner motor. Attach the kit-supplied red
the manifold pressure to be checked in the next Section “LPG” label, P/N 22500-0065, on top of the “NAT” label.
of these instructions. The new label should completely cover the “NAT” label.
Figure 7 See Figure 8.
Flame sensor ( + ) 3. Complete the information on the Gas Conversion Label
as shown in Figure 8.
4. Attach the Gas Conversion Label in plain view on the
outside of the oven, as close as possilble to the oven’s
Pilot hood ( - ) serial plate.

Figure 8
Attach on top of
existing “NAT”
label (on burner or
burner motor)
Attach to gas
piping next to New label completely
combination covers “NAT” label
gas valve Name of Date of
technician conversion

Measured value
from Section X

Part no. of this

Kit - see chart
on Page 1

Attach completed label in plain

Stated on the oven’s See chart on view near serial plate
serial plate Page 1
6

124
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for All Gas Conversion Kits

for Ovens with Wayne Burner, Propane to Natural Gas, 8/00

Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • USA • (847) 741-3300 • FAX (847) 741-4406

Instructions for Service Kits 42810-0120, 42810-0125, 42810-0126, 42810-0127, 43061, 44664
Gas Conversion Kit for Middleby Marshall Ovens
Propane to Natural Gas Operation
KIT COMPONENTS:
Qty. PS200 PS220/224 PS310/360 PS360WB PS360WB70/EWB PS555 PS570S Description

1 42810-0125 42810-0126 42810-0120 42810-0127 44664 43061 42810-0127 KIT, GAS CONVERSION, PROPANE

ENGLISH - page 1
TO NATURAL
1 22176-0010 22176-0016 22176-0004 22176-0014 22176-0014 43059 22176-0014 ORIFICE, MAIN
0.204”/5.18mm 0.182”/4.62mm 0.219”/5.56mm 0.250”/6.35mm 0.250”/6.35mm 0.228”/5.79mm 0.250”/6.35mm
1 < - - - - - - - - - - - - - - - - - - - - - - - - 22174-0011 - - - - - - - - - - - - - - - - - - - - - - - - > ORIFICE, PILOT
0.028”/0.71mm
1 22174-0006 22174-0006 22174-0006 22174-0006 22174-0006 * NONE * 22174-0006 * ORIFICE, BYPASS (HIGH-FLAME)
0.060”/1.52mm/ 0.060”/1.52mm/ 0.060”/1.52mm/ 0.060”/1.52mm/ 0.060”/1.52mm/ 0.060”/1.52mm/
#53 drill #53 drill #53 drill #53 drill #53 drill #53 drill
1 < - - - - - - - - - - - - - - - - - - - - - - - - 28092-0019 - - - - - - - - - - - - - - - - - - - - - - - - > KIT, GAS CONTROL VALVE SPRING
- NATURAL GAS
1 < - - - - - - - - - - - - - - - - - - - - - - - - 22500-0064 - - - - - - - - - - - - - - - - - - - - - - - - > LABEL, NATURAL GAS (YELLOW/
GREEN)
1 < - - - - - - - - - - - - - - - - - - - - - - - - 22500-0123 - - - - - - - - - - - - - - - - - - - - - - - - > LABEL, GAS CONVERSION
1 < - - - - - - - - - - - - - - - - - - - - - - - - 22501-0007 - - - - - - - - - - - - - - - - - - - - - - - - > TAG, GAS CONTROL CONVERSION
1 < - - - - - - - - - - - - - - - - - - - - - - - - 88210-0070 - - - - - - - - - - - - - - - - - - - - - - - - > INSTRUCTIONS

ESPAÑOL - página 7
* NOTE: The bypass orifice is not used if the oven is equipped with a modulating gas valve. These ovens include:
• PS360EWB (all)
• PS555 (all)
• PS570S (units produced 4/00 or later)
For additional information, refer to Part III of these instructions (Bypass Orifice Conversion).

IMPORTANT
THIS CONVERSION KIT IS INTENDED FOR AGA-, CGA-, AND CSA-APPROVED MIDDLEBY
MARSHALL GAS-FIRED OVENS OPERATING AT ALTITUDES UP TO 5000 FT. (1524m).
FOR OVENS INSTALLED AT ALTITUDES ABOVE 5000 FT. (1524m), CONSULT THE FAC-
TORY BEFORE INSTALLING THIS KIT.
THIS KIT MAY NOT BE USED WITH CE-APPROVED MIDDLEBY MARSHALL OVENS.
FOR THESE OVENS, FOLLOW THE GAS CONVERSION INSTRUCTIONS IN THE INSTAL-
LATION SECTION OF THE OVEN’S OWNER’S OPERATING AND INSTALLATION MANUAL.

WARNING
THIS CONVERSION KIT IS TO BE INSTALLED BY A MIDDLEBY MARSHALL AUTHORIZED SERVICE AGENT
IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS AND ALL CODES AND REQUIREMENTS
OF THE AUTHORITY HAVING JURISDICTION. FAILURE TO FOLLOW INSTRUCTIONS COULD RESULT IN
SERIOUS INJURY OR PROPERTY DAMAGE. THE AUTHORIZED SERVICE AGENT PERFORMING THIS
WORK ASSUMES RESPONSIBILITY FOR THIS CONVERSION.

WARNING
BEFORE PERFORMING ANY SERVICE WORK, THE ELECTRICAL POWER SUPPLY AND THE GAS SUP-
PLY MUST BE TURNED OFF.

1 P/N 88210-0070 • Rev. C • V1 • 8/00

125
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for All Gas Conversion Kits

for Ovens with Wayne Burner, Propane to Natural Gas, 8/00
Typical PS200-series gas train configuration
Burner
blower
Solenoid
valve
Pilot line

Combination gas
control valve
(safety regulator) Burner
ENGLISH

Bypass Pilot pressure

line tap (pilot tee)

Gas pipe union

Typical PS300-series gas train configuration

Burner Modulating gas

blower valve (if so
equipped)

Solenoid valve
(if so equipped)
Combination gas
control valve
(safety regulator) Bypass
line Burner
Gas pipe
union
Pilot line

Manual
shutoff valve Pilot pressure tap (pilot tee)

Typical PS555 or PS570S gas train configuration

Modulating gas
Burner valve (if so
Burner blower equipped)
Solenoid valve
(if so equipped)
Combination gas
control valve
(safety regulator) Bypass
line

Pilot
line
Pilot pressure
Manual Gas pipe tap (pilot tee)
shutoff valve union
2

126
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for All Gas Conversion Kits

for Ovens with Wayne Burner, Propane to Natural Gas, 8/00
I. PREPARATION AND DISASSEMBLY Figure 1
1. Turn off the electric power supply to the oven.
2. Turn off the gas supply at the service valve behind the
oven.
3. Open the machinery compartment door. Hex
screws
4. Open the union in the gas supply line. The union is
located on the inlet side of the combination gas control
valve. See Figure 1. Gas pipe
union
5. Unscrew the four hex screws that hold the venturi
mounting plate to the front of the burner. Remove the
gas train/venturi assembly from the oven.

ENGLISH
II. COMBINATION GAS CONTROL VALVE (SAFETY
REGULATOR) CONVERSION PS570S gas train (with solenoid valve) shown.
Refer to the illustrations on Page 2 for
1. Remove and discard the following components from the component placement for other oven models.
combination gas control valve, as shown in Figure 2:
• Regulator cap screw
• Regulator adjustment screw
• Regulator spring
Figure 2
2. Install the stainless steel kit-supplied regulator spring,
with the tapered end facing into the valve, as shown in
Figure 2.
3. Install the kit-supplied regulator adjustment screw.
Carefully adjust the screw until its top is flush with the
top of the regulator.
4. Turn the adjustment screw six complete turns in a
clockwise direction. This preliminary pressure setting
Adjustment
is approximately 3-1/2” W.C. (8.7mbar). screw
5. Install the silver kit-supplied cap screw.

III. BYPASS ORIFICE CONVERSION Regulator

spring
NOTE: Ovens are equipped with EITHER an on-off solenoid
valve with a separate bypass line, OR with a modulating gas
valve. Refer to the illustrations on Page 2. When installing
this Kit, the bypass orifice will only be changed if the oven Cap screw
is equipped with a solenoid valve.
• If the oven is equipped with a modulating gas valve, skip
ahead to Section IV, Pilot Orifice Conversion.
• If the oven is equipped with a solenoid valve, continue on
Figure 3
to Step 1, below.
1. Unscrew the compression nuts at both ends of the Compression
bypass tube, and slide them back and out of the way. nut
Then, remove and retain the tubing. See Figure 3.
2. Remove and discard the existing bypass orifice.
3. Slip the kit-supplied bypass orifice into the discharge
end of the bypass tube, as shown in Figure 3. Bypass
4. With the orifice in place, push the tube back into the orifice
compression fittings until it bottoms.
5. While holding the tube in place, slide the compression
nuts into place. Tighten them to a snug fit with your
fingers. Bypass
tube
6. Gently tighten the nuts one complete turn with a
wrench. DO NOT OVERTIGHTEN THE COMPRESSION
NUTS. 3

127
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for All Gas Conversion Kits

for Ovens with Wayne Burner, Propane to Natural Gas, 8/00
IV. PILOT ORIFICE CONVERSION Figure 4
1. Unscrew the two 1/2" nuts that secure the gas train to
Venturi
the venturi mounting plate. See Figure 4.
2. Unscrew the pilot tube compression nut, and slide it out Spark
of the way. Then, pull the tube from the fitting to expose cable
the pilot orifice. See Figure 4.
3. Separate the venturi, mounting plate, and gas train
assembly. Leave the main orifice holder attached to the
gas train piping assembly.
4. Remove and discard the existing pilot orifice. Pilot
orifice
5. Slip the kit-supplied pilot orifice into the pilot tube.
6. With the orifice in place, push the tube back into the
ENGLISH

compression fitting until it bottoms.

7. While holding the tube in place, slide the compression Compression
nut into place. Tighten the nut to a snug fit with your nut
fingers. Orifice
holder
8. Gently tighten the nut one complete turn with a wrench.
DO NOT OVERTIGHTEN THE COMPRESSION NUT.
9. To allow the main orifice to be replaced, do not reassemble Main
orifice
the gas train to the venturi and mounting plate at this
time.

V. MAIN ORIFICE CONVERSION

1. Unscrew the existing main orifice from its holder using 1/2” hex nuts
an 11/16” wrench. See Figure 4.
2. Install the kit-supplied main orifice into the holder.

VI. REASSEMBLY
1. Check that the pilot assembly is correctly aligned with
the venturi, as shown in Figure 5. If necessary,
reposition the pilot assembly.
2. Reassemble the venturi and mounting plate to the gas
train assembly. Replace the two 1/2” hex nuts to hold
the assembly together.
3. Replace the assembled gas train into the oven. Tighten
the gas pipe union (on the inlet side of the combination
gas valve) to hold the gas train in place.

Figure 5
View from side of venturi View from rear of venturi

Rear edge
of pilot
hood is on
centerline
of venturi

Pilot hood

3/8” (9.5mm) 11/16” (17.5mm)

128
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for All Gas Conversion Kits

for Ovens with Wayne Burner, Propane to Natural Gas, 8/00
VII. GAS LEAK TEST VIII. INLET PRESSURE CHECK
1. Restore the electrical and gas utility connections to the 1. Using a manometer, check the inlet pressure at the inlet
oven. pressure tap. See Figure 6. An inlet pressure of 6-12”
2. Paint all gas pipe connections from the union to the W.C. (14.9-29.9mbar) is recommended for natural gas
venturi mounting plate, as well as the pilot tubing, operation.
bypass tubing, and pressure tap plug, with a rich 2. If the inlet pressure is:
solution of soap and water (2/3 soap, 1/3 water is • HIGHER THAN 14” W.C. (34.9mbar) - This pressure
recommended). Any visible bubbles indicate a gas may damage the combination gas control valve
leak. (safety regulator). The gas supply pressure should
3. If a gas leak is detected, tighten the affected joints and be decreased.
connections. If tightening the connection(s) fails to stop • LOWER THAN 6” W.C. (14.9mbar) - It may be
the leak: necessary to increase the supplied gas pressure.
• Turn off the electric power supply to the oven.

ENGLISH
• Turn off the gas supply at the service valve behind CAUTION
the oven. IF IT IS NECESSARY TO ADJUST THE GAS LINE
• Replace the affected component(s). PRESSURE, HAVE THE CUSTOMER CONTACT THE
GAS UTILITY SUPPLIER.
• Repeat the gas leak test.
WARNING - FIRE/EXPLOSION HAZARD
HIDDEN GAS LEAKS CAN CAUSE A FLASHBACK IX. PILOT PRESSURE ADJUSTMENT
IN THE MACHINERY COMPARTMENT. THIS
CAN CAUSE SEVERE INJURY OR DEATH. 1. Unscrew the cap plug from the pilot pressure tap (pilot
STAND WELL CLEAR WHEN SWITCHING ON tee), and attach a manometer to the tap. See Figure 6.
THE HEATING CIRCUIT. 2. Remove the pilot adjustment cap screw from the
4. If no leaks are detected by the test, depress the safety combination gas control valve.
switch(es) and switch on the oven. Then, switch on the 3. Turn the oven on, and allow it to heat to temperature.
heating circuit to ignite the burner. Make a note of the customer’s set point temperature.
5. With the burner in operation, paint all gas pipe joints with 4. After the oven has heated, adjust the set point of the
the solution of soap and water. oven far lower than its current (operating) temperature.
6. If any further gas leaks are detected, shut down the This ensures that the pilot flame will be at its lowest level
oven. Reseal and tighten the affected joints and for some time.
connections. If tightening the connection(s) fails to stop Continued...
the leak:
• Turn off the electric power supply to the oven.
• Turn off the gas supply at the service valve behind
the oven.
• Replace the affected component(s).
• Repeat the gas leak test.
Figure 6
Adjust manifold
pressure here
(under cap screw)

Measure
Measure inlet
manifold
pressure here
pressure here

Measure pilot
pressure here
(under cap plug) Adjust pilot
pressure here
(under cap screw)
5

129
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for All Gas Conversion Kits

for Ovens with Wayne Burner, Propane to Natural Gas, 8/00
5. The pilot pressure should be adjusted as follows: X. MANIFOLD PRESSURE ADJUSTMENT
• The current flow between the pilot hood and the 1. Remove the regulator cap screw from the combination
flame sensor, when measured with a microamp gas control valve.
meter or multimeter, holds constant at a minimum 2. Using a manometer, check the pressure at the manifold
of 2.0 µA. See Figure 7. pressure tap, as shown in Figure 6. A manifold pressure
• The pilot pressure as shown on the manometer is in of 3-1/2” W.C. (8.7mbar) is recommended for natural
the range of 3-1/2” - 4” W.C. (8.7-10.0 mbar). gas operation.
Adjust the pilot pressure as necessary by turning the 3. Adjust the pressure as necessary by turning the
pilot adjustment screw on the combination gas control adjustment screw on the combination gas control valve.
valve. Turning the screw clockwise decreases the pilot Turning the screw clockwise decreases the pressure.
pressure. Turning the screw counter-clockwise increases Turning the screw counter-clockwise increases the
ENGLISH - page 1

the pressure. pressure.

Some valves may have a burr in the pilot adjustment If the manifold pressure cannot be properly adjusted,
portal. If you have fully tightened the adjustment screw, switch the oven off and allow it to cool; then, replace the
and the manometer still does not register a change in combination gas control valve. Repeat Section VII (Gas
pressure, continue to tighten the screw to break through Leak Test) before attempting to adjust the manifold
the burr. Back the screw out until its top is flush with the pressure again.
top of its hole, then tighten the screw again as necessary 4. After the manifold pressure has been properly adjusted,
to adjust the pressure. Repeat this procedure as replace the cap screw. Record the final value on the Gas
necessary to properly adjust the pilot pressure. Conversion Label, as shown in Figure 8.
If the pilot pressure cannot be properly adjusted, switch 5. Switch the oven off, and allow it to cool.
the oven off and allow it to cool; then, replace the
combination gas control valve. Repeat Section VII (Gas
Leak Test) before attempting to adjust the pilot pressure XI. MARKING AND LABELING
ESPAÑOL - página 7

again. 1. Print the word “NATURAL” in the space provided on the

7. After the pilot pressure has been properly adjusted, Gas Control Conversion Tag, P/N 22501-0007. See
replace the cap screw. Figure 8. Fasten the tag onto the gas piping next to the
combination gas control valve.
8. Reset the oven’s set point temperature to the customer’s
original settings. Leave the oven in operation to allow 2. Locate the round “LPG” label (red) on the burner or
the manifold pressure to be checked in the next Section burner motor. Attach the kit-supplied yellow/green
of these instructions. “NAT” label, P/N 22500-0064, on top of the “LPG” label.
The new label should completely cover the “LPG” label.
Figure 7 See Figure 8.
Flame sensor ( + )
3. Complete the information on the Gas Conversion Label
as shown in Figure 8.
4. Attach the Gas Conversion Label in plain view on the
Pilot hood ( - ) outside of the oven, as close as possilble to the oven’s
serial plate.

Figure 8
Attach on top of
existing “LPG”
label (on burner or
burner motor)
Attach to gas
piping next to New label completely
combination covers “LPG” label
gas valve Name of Date of
technician conversion

Measured value
from Section X

Part no. of this

Kit - see chart
on Page 1

Attach completed label in plain

Stated on the oven’s See chart on view near serial plate
serial plate Page 1
6

130
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 36856 - Gas Conversion Kit for
PS360EWB/WB70 with Midco Burner, Natural Gas to Propane, 1/98

Middleby
Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • (847)741-3300 • FAX (847)741-4406 Marshall®
Oven Gas Conversion Kit p/n 36856
PS360EWB and PS360WB70
Natural Gas to Propane Installation Instructions
WARNING
This conversion kit is to be installed by a Middleby Marshall Authorized Service Organization in accordance with
the manufacturer’s instructions and all codes and requirements of the authority having jurisdiction. Failure to
follow instructions could result in serious injury or property damage. The authorized service organization
performing this work assumes responsibility for this conversion.

This kit consists of the following parts:

Qty. Units p/n Description

1 ea. 36857 Instructions for Conversion of Natural Gas Operation to Propane Operation, PS360EWB and
PS360WB70
1 ea. 31819 Orifice, Pilot Assembly - Propane, 0.025” (0.64mm)
1 ea. 31822 Orifice, Main - Propane, 0.185” (4.70mm)
1 ea. 22174-0009 Orifice, Low Flame - Propane, 0.034” (0.86mm, #62 drill) - used for converting PS360WB70 only
1 ea. 22500-0065 Label, LPG, Red
1 ea. 22500-0123 Label, Conversion - Gas

IMPORTANT
When converting any oven that is installed at an altitude above 5000 ft. (1524m), consult Middleby before installing
this Kit.

1. PREPARATION
1.1 Turn off the electric power supply to the oven.

1.2 Turn off the gas supply at the service valve behind the oven.

WARNING
Before performing any service or conversion work, the electrical power supply AND the gas supply MUST be
turned off.

1.3 Open the machinery compartment access door.

2. PILOT ORIFICE REPLACEMENT

2.1 Unscrew the brass fittings at both ends of the aluminum pilot tubing that connects the pilot orifice to the combination gas control
valve. This allows the tubing to be removed. See Figure 1.

Figure 1
Conversion component locations

Solenoid valve
(PS360WB70 only) Main
orifice
Low flame bypass holder
(PS360WB70 only)

Combination gas
control valve
Pilot
orifice

Aluminum
pilot tubing

p/n 36857 P. Jan 98 Rev. B Page 1 of 4

131
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 36856 - Gas Conversion Kit for
PS360EWB/WB70 with Midco Burner, Natural Gas to Propane, 1/98
2.2 Remove and retain the aluminum pilot tubing from the burner Figure 2
assembly. The end of the tubing that enters the combination gas
control valve should be removed first. Pilot orifice assembly

2.3 Remove and retain the pilot orifice by unscrewing it (counterclockwise) Pilot tubing connector
from the burner plenum wall.

2.4 Unscrew and retain the pilot tubing connector and the pilot tap plug Pilot tap plug
from the ends of the pilot orifice, as shown in Figure 2. When these
attachments have been removed, discard the pilot orifice.
Pilot orifice
2.5 Screw the pilot tubing connector and the pilot tap plug into place in
the new propane pilot orifice (p/n 31819). Tighten them to a snug fit.

2.6 Screw the new propane pilot orifice into its opening in the plenum Figure 3
wall. Tighten it to a snug fit. Ensure that the end of the orifice holding Main orifice and holder
the pilot tubing mount points towards the piping assembly.
Main orifice
2.7 Replace the aluminum pilot tubing that was removed in Step 2.2, above.
holder
2.8 Screw in the brass fittings at both ends of the aluminum pilot tubing.
Tighten them to a snug fit. DO NOT OVERTIGHTEN THE FITTINGS.

3. MAIN ORIFICE REPLACEMENT Main orifice

3.1 Remove and retain the main orifice holder by unscrewing it
(counterclockwise) from the burner plenum wall.
Main manifold tap
3.2 Unscrew and discard the main orifice from the inner end of the holder, plug (leave in place)
as shown in Figure 3.

3.3 Screw the new propane main orifice (p/n 31822) into the orifice holder.
Tighten it to a snug fit.

3.4 Replace the main orifice holder into its opening in the burner plenum. Figure 4
Tighten it to a snug fit.
Low flame orifice replacement
4. LOW FLAME ORIFICE REPLACEMENT (PS360WB70 only) Aluminum
tubing
4.1 Unscrew the brass fittings at both ends of the aluminum low flame
tubing. This allows the tubing to be removed. See Figure 4.

4.2 Remove and retain the tubing from the solenoid valve.

4.3 Remove and discard the low flame orifice from the end of the low Low flame rn e r
u
flame tubing. To b
orifice

4.4 Insert the new propane low flame orifice (p/n 22174-0009) into the
discharge end of the low flame tubing, as shown in Figure 4.

4.5 Replace the low flame tubing into the fittings on the solenoid valve. tion
bina e
com alv
From ontrol v
s c
4.6 Screw in the brass fittings at both ends of the aluminum low flame ga
tubing. Tighten them to a snug fit. Solenoid valve
5. GAS LEAK TEST
5.1 Paint all pipe connections from the gas union to the burner plenum, and the aluminum pilot and low flame orifice tubing connections,
with a solution of soap and water (2/3 soap, 1/3 water is recommended). Any bubbles that are visible indicate a gas leak.

5.2 If a gas leak is detected, tighten the affected joints and connections. If tightening the connections fails to stop the leak, replace
the affected component and repeat the gas leak test.

WARNING - FIRE / EXPLOSION HAZARD

Hidden gas leaks can cause a flashback in the machinery compartment. THIS CAN CAUSE SEVERE INJURY OR
DEATH. Stand well clear when switching on the heating circuit.

5.3 If no leaks are detected by the test, switch on the oven. Switch on the heating circuit to ignite the main burner.

5.4 With the burner in operation, paint all gas pipe joints with the solution of soap and water.

5.5 If any further gas leaks are detected, shut down the oven. Reseal and tighten the affected joints and connections. If tightening
the connections fails to stop the leak, replace the affected component(s) and repeat the gas leak test.

Page 2 of 4 P. Jan 98 Rev. B p/n 36857

132
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 36856 - Gas Conversion Kit for
PS360EWB/WB70 with Midco Burner, Natural Gas to Propane, 1/98
6. INLET PRESSURE CHECK
6.1 Check the gas control inlet pressure at the inlet pressure tap. See Figure 6. An inlet pressure of 6-14” (14.9-34.9mbar) is
recommended for propane operation.
6.2 If the inlet pressure is:
• HIGHER THAN 14” W. C. (34.9mbar) - This pressure may damage the combination gas control valve. Decrease the supplied
gas pressure.
• LOWER THAN 3” W. C. (7.46mbar) - It may be necessary to increase the supplied gas pressure.
If it is necessary to adjust the gas line pressure, have the customer contact the gas utility supplier.

7. PILOT PRESSURE ADJUSTMENT

7.1 Ensure that the air supply is properly adjusted for propane operation.
• Units with a burner blower air shutter (see Figure 5) should have the shutter opening (at its outside edge) set to 5/16”
(7.94mm). A drill bit can be used to check the adjustment of this opening.
• Units without the air shutter (see Figure 5) should have the burner air supply adjustment screw turned 11-17 full revolutions
clockwise from the fully closed (counterclockwise) position. The screw is located on the front wall of the burner plenum, and
is surrounded by a “MORE AIR” label.
Figure 5
Burner blower configurations
Insert a 5/16” Blowers without
(7.94mm) drill
bit to measure
external air shutter
opening
(remove before
operation) External
air
shutter OR

7.2 Before proceeding:

• For a PS360EWB oven, the set point should be reduced
below the room temperature.
• For a PS360WB70 oven, set the oven to low flame. Figure 6
Gas pressure measurement/adjustment locations
7.3 Measure the pilot pressure at the pilot pressure tap, as shown
in Figure 6. The gas pressure should be 5-6” W. C. (12.5-
14.9mbar) for proper operation. Pressure Pilot tube
regulator cap connects
7.4 If necessary, adjust the pilot pressure as follows: screw here
• Remove the pilot adjustment cap screw.
• Using a screwdriver, turn the inner adjustment screw
counterclockwise to increase, or clockwise to decrease,
the pilot gas pressure.
• Replace the cap screw and tighten it firmly. Pilot
Inlet pressure adjustment
7.5 Measure the current across the pilot flame sensor. The tap cap screw
current must measure at least 2.0 µA. If the current reading
is too low, recheck the pilot pressure as per Step 7.3. If the
pressure reading is correct, consult the factory; otherwise,
repeat Steps 7.4 and 7.5. Main orifice
pressure tap
8. MAIN MANIFOLD PRESSURE ADJUSTMENT
8.1 With the oven set to high flame, measure the regulated gas
pressure to the burner. The outlet pressure should be
checked at the main orifice pressure tap. See Figure 6.
The gas pressure should be 3” W. C. (7.46mbar) for proper
operation. Pilot pressure
tap
8.2 If necessary, adjust the pressure regulator as follows:
• Remove the pressure regulator cap screw.
• Using a screwdriver, turn the inner adjustment screw clockwise to increase, or counterclockwise to decrease, the main
burner gas pressure.
• Replace the cap screw and tighten it firmly.

8.3 Record the final measured regulated gas pressure on the silver conversion information label (included in the kit).

p/n 36857 P. Jan 98 Rev. B Page 3 of 4

133
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 36856 - Gas Conversion Kit for
PS360EWB/WB70 with Midco Burner, Natural Gas to Propane, 1/98
9. CONVERSION LABELING Figure 7
Red “LPG.” label placement
9.1 Remove and discard the round, green “NAT.” label from the (on burner housing)
front face of the burner plenum.

9.2 Apply the round, red “LPG.” label (p/n 22500-0065) to the front
face of the burner housing as shown in Figure 7.

9.3 Close the machinery compartment access door.

9.4 Record the information requested on the silver conversion

information label. Figure 8 shows a representation of this label.

9.5 Apply the conversion information label to the front of the

machinery compartment access door, next to the control panel. Upper oven Lower oven
See Figure 9. label location label location

Figure 8
Conversion information label
Signature of technician
Date of conversion
performing conversion

PROPANE
THIS APPLIANCE HAS BEEN CONVERTED ON _______________ TO ______________ GAS WITH KIT
36856
NO. ________________ BY _______________ , WHO ACCEPTS THE RESPONSIBILITY FOR
THE CORRECTNESS OF THIS CONVERSION.

MODEL NO. MAIN BURNER ORIFICE SIZE .185”/4.70mm MANIFOLD PRESSURE

INPUT RATING 175,000 BTU MAXIMUM INLET PRESSURES 14” W.C./34.9mbar

Stated on the Measured value

oven’s data plate recorded in Step 8.3

Figure 9
Conversion information label placement

THIS APPLIANCE HAS BEEN CONVERTED ON _______________ TO ______________ GAS WITH KIT
NO. ________________ BY _______________ , WHO ACCEPTS THE RESPONSIBILITY FOR
THE CORRECTNESS OF THIS CONVERSION.

MODEL NO. MAIN BURNER ORIFICE SIZE MANIFOLD PRESSURE

INPUT RATING MAXIMUM INLET PRESSURES

PS360EWB placement

THIS APPLIANCE HAS BEEN CONVERTED ON _______________ TO ______________ GAS WITH KIT
NO. ________________ BY _______________ , WHO ACCEPTS THE RESPONSIBILITY FOR
THE CORRECTNESS OF THIS CONVERSION.

MODEL NO. MAIN BURNER ORIFICE SIZE MANIFOLD PRESSURE

INPUT RATING MAXIMUM INLET PRESSURES

PS360WB70 placement

Page 4 of 4 P. Jan 98 Rev. B p/n 36857

134
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 36863 - Gas Conversion Kit for
PS360EWB/WB70 with Midco Burner, Propane to Natural Gas, 1/98

Middleby
Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • (847)741-3300 • FAX (847)741-4406 Marshall®
Oven Gas Conversion Kit p/n 36863
PS360EWB and PS360WB70
Propane to Natural Gas Installation Instructions
WARNING
This conversion kit is to be installed by a Middleby Marshall Authorized Service Organization in accordance with
the manufacturer’s instructions and all codes and requirements of the authority having jurisdiction. Failure to
follow instructions could result in serious injury or property damage. The authorized service organization
performing this work assumes responsibility for this conversion.

This kit consists of the following parts:

Qty. Units p/n Description

1 ea. 36862 Instructions for Conversion of Propane Operation to Natural Gas Operation, PS360EWB and
PS360WB70
1 ea. 31818 Orifice, Pilot Assembly - Natural Gas, 0.032” (0.81mm)
1 ea. 31821 Orifice, Main - Natural Gas, 0.234” (5.94mm)
1 ea. 22174-0006 Orifice, Low Flame - Nat. Gas, 0.065” (1.65mm, #53 drill) - used for converting PS360WB70 only
1 ea. 22500-0064 Label, NAT, Green
1 ea. 22500-0123 Label, Conversion - Gas

IMPORTANT
When converting any oven that is installed at an altitude above 5000 ft. (1524m), consult Middleby before installing
this Kit.

1. PREPARATION
1.1 Turn off the electric power supply to the oven.

1.2 Turn off the gas supply at the service valve behind the oven.

WARNING
Before performing any service or conversion work, the electrical power supply AND the gas supply MUST be
turned off.

1.3 Open the machinery compartment access door.

2. PILOT ORIFICE REPLACEMENT

2.1 Unscrew the brass fittings at both ends of the aluminum pilot tubing that connects the pilot orifice to the combination gas control
valve. This allows the tubing to be removed. See Figure 1.

Figure 1
Conversion component locations

Solenoid valve
(PS360WB70 only) Main
orifice
Low flame bypass holder
(PS360WB70 only)

Combination gas
control valve
Pilot
orifice

Aluminum
pilot tubing

p/n 36862 P. Jan. 98 Rev B Page 1 of 4

135
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 36863 - Gas Conversion Kit for
PS360EWB/WB70 with Midco Burner, Propane to Natural Gas, 1/98
2.2 Remove and retain the aluminum pilot tubing from the burner Figure 2
assembly. The end of the tubing that enters the combination gas
control valve should be removed first. Pilot orifice assembly
Pilot tubing connector
2.3 Remove and retain the pilot orifice by unscrewing it (counterclockwise)
from the burner plenum wall.

2.4 Unscrew and retain the pilot tubing connector and the pilot tap plug Pilot tap plug
from the ends of the pilot orifice, as shown in Figure 2. When these
attachments have been removed, discard the pilot orifice.
Pilot orifice
2.5 Screw the pilot tubing connector and the pilot tap plug into place in
the new propane pilot orifice (p/n 31819). Tighten them to a snug fit.

2.6 Screw the new propane pilot orifice into its opening in the plenum Figure 3
wall. Tighten it to a snug fit. Ensure that the end of the orifice holding Main orifice and holder
the pilot tubing mount points towards the piping assembly.
Main orifice
2.7 Replace the aluminum pilot tubing that was removed in Step 2.2, above.
holder
2.8 Screw in the brass fittings at both ends of the aluminum pilot tubing.
Tighten them to a snug fit. DO NOT OVERTIGHTEN THE FITTINGS.

3. MAIN ORIFICE REPLACEMENT Main orifice

3.1 Remove and retain the main orifice holder by unscrewing it
(counterclockwise) from the burner plenum wall.
Main manifold tap
3.2 Unscrew and discard the main orifice from the inner end of the holder, plug (leave in place)
as shown in Figure 3.

3.3 Screw the new natural gas main orifice (p/n 31821) into the orifice
holder. Tighten it to a snug fit.

3.4 Replace the main orifice holder into its opening in the burner plenum. Figure 4
Tighten it to a snug fit.
Low flame orifice replacement
4. LOW FLAME ORIFICE REPLACEMENT (PS360WB70 only) Aluminum
tubing
4.1 Unscrew the brass fittings at both ends of the aluminum low flame
tubing. This allows the tubing to be removed. See Figure 4.

4.2 Remove and retain the tubing from the solenoid valve.

4.3 Remove and discard the low flame orifice from the end of the low Low flame rn e r
u
flame tubing. To b
orifice

4.4 Insert the new natural gas low flame orifice (p/n 22174-0006) into the
discharge end of the low flame tubing, as shown in Figure 4.

4.5 Replace the low flame tubing into the fittings on the solenoid valve. tion
bina e
com alv
From ontrol v
s c
4.6 Screw in the brass fittings at both ends of the aluminum low flame ga
tubing. Tighten them to a snug fit. Solenoid valve
5. GAS LEAK TEST
5.1 Paint all pipe connections from the gas union to the burner plenum, and the aluminum pilot and low flame orifice tubing connections,
with a solution of soap and water (2/3 soap, 1/3 water is recommended). Any bubbles that are visible indicate a gas leak.

5.2 If a gas leak is detected, tighten the affected joints and connections. If tightening the connections fails to stop the leak, replace
the affected component and repeat the gas leak test.

WARNING - FIRE / EXPLOSION HAZARD

Hidden gas leaks can cause a flashback in the machinery compartment. THIS CAN CAUSE SEVERE INJURY OR
DEATH. Stand well clear when switching on the heating circuit.

5.3 If no leaks are detected by the test, switch on the oven. Switch on the heating circuit to ignite the main burner.

5.4 With the burner in operation, paint all gas pipe joints with the solution of soap and water.

5.5 If any further gas leaks are detected, shut down the oven. Reseal and tighten the affected joints and connections. If tightening
the connections fails to stop the leak, replace the affected component(s) and repeat the gas leak test.

Page 2 of 4 P. Jan. 98 Rev B p/n 36862

136
 SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 36863 - Gas Conversion Kit for
PS360EWB/WB70 with Midco Burner, Propane to Natural Gas, 1/98
6. INLET PRESSURE CHECK
6.1 Check the gas control inlet pressure at the inlet pressure tap. See Figure 6. An inlet pressure of 6-14” (14.9-34.9mbar) is
recommended for natural gas operation.
6.2 If the inlet pressure is:
• HIGHER THAN 14” W. C. (34.9mbar) - This pressure may damage the combination gas control valve. Decrease the supplied
gas pressure.
• LOWER THAN 3” W. C. (7.46mbar) - It may be necessary to increase the supplied gas pressure.
If it is necessary to adjust the gas line pressure, have the customer contact the gas utility supplier.

7. PILOT PRESSURE ADJUSTMENT

7.1 Ensure that the main burner primary air supply is properly adjusted for natural gas operation.
• Units with a burner blower air shutter (see Figure 5) should have the shutter opening (at its outside edge) set to 5/16”
(7.94mm). A drill bit can be used to check the adjustment of this opening.
• Units without the air shutter (see Figure 5) should have the burner air supply adjustment screw turned 11-17 full revolutions
clockwise from the fully closed (counterclockwise) position. The screw is located on the front wall of the burner plenum, and
is surrounded by a “MORE AIR” label.
Figure 5
Burner blower configurations
Insert a 5/16” Blowers without
(7.94mm) drill
bit to measure
external air shutter
opening
(remove before
operation) External
air
shutter OR

7.2 Before proceeding:

• For a PS360EWB oven, the set point should be reduced
below the room temperature. Figure 6
• For a PS360WB70 oven, set the oven to low flame. Gas pressure measurement/adjustment locations

7.3 Measure the pilot pressure as shown in Figure 6. The gas Pressure Pilot tube
pressure should be 5-6” W. C. (12.5-14.9mbar) for proper
operation. regulator cap connects
screw here
7.4 If necessary, adjust the pilot pressure as follows:
• Remove the pilot adjustment cap screw.
• Using a screwdriver, turn the inner adjustment screw
counterclockwise to increase, or clockwise to decrease, Pilot
the pilot gas pressure. Inlet pressure adjustment
• Replace the cap screw and tighten it firmly. tap cap screw
7.5 Measure the current across the pilot flame sensor. The
current must measure at least 2.0 µA. If the current reading
is too low, recheck the pilot pressure as per Step 7.3. If the
pressure reading is correct, consult the factory; otherwise, Main orifice
repeat Steps 7.4 and 7.5. pressure tap

8. MAIN MANIFOLD PRESSURE ADJUSTMENT

8.1 With the oven set to high flame, measure the regulated gas
pressure to the burner. The outlet pressure should be
checked at the main orifice pressure tap. See Figure 6.
The gas pressure should be 3” W. C. (7.46mbar) for proper Pilot pressure
operation. tap
8.2 If necessary, adjust the pressure regulator as follows:
• Remove the pressure regulator cap screw.
• Using a screwdriver, turn the inner adjustment screw clockwise to increase, or counterclockwise to decrease, the main
burner gas pressure.
• Replace the cap screw and tighten it firmly.

8.3 Record the final measured regulated gas pressure on the silver conversion information label (included in the kit).
p/n 36862 P. Jan. 98 Rev B Page 3 of 4

137
SECTION 3 - SERVICING COMPONENTS

Appendix - Instructions for Service Kit 36863 - Gas Conversion Kit for
PS360EWB/WB70 with Midco Burner, Propane to Natural Gas, 1/98
9. CONVERSION LABELING Figure 7
Yellow “NAT.” label placement
9.1 Remove and discard the round, red “LPG.” label from the front (on burner housing)
face of the burner plenum.

9.2 Apply the round, green “NAT.” label (p/n 22500-0064) to the
front face of the burner housing as shown in Figure 7.

9.3 Close the machinery compartment access door.

9.4 Record the information requested on the silver conversion

information label. Figure 8 shows a representation of this label.

9.5 Apply the conversion information label to the front of the

machinery compartment access door, next to the control panel. Upper oven Lower oven
See Figure 9. label location label location

Figure 8
Conversion information label
Signature of technician
Date of conversion
performing conversion

NATURAL
THIS APPLIANCE HAS BEEN CONVERTED ON _______________ TO ______________ GAS WITH KIT
36863
NO. ________________ BY _______________ , WHO ACCEPTS THE RESPONSIBILITY FOR
THE CORRECTNESS OF THIS CONVERSION.

MODEL NO. MAIN BURNER ORIFICE SIZE .234”/5.94mm MANIFOLD PRESSURE

INPUT RATING 175,000 BTU MAXIMUM INLET PRESSURES 14” W.C./34.9mbar

Stated on the Measured value

oven’s data plate recorded in Step 8.3

Figure 9
Conversion information label placement

THIS APPLIANCE HAS BEEN CONVERTED ON _______________ TO ______________ GAS WITH KIT
NO. ________________ BY _______________ , WHO ACCEPTS THE RESPONSIBILITY FOR
THE CORRECTNESS OF THIS CONVERSION.

MODEL NO. MAIN BURNER ORIFICE SIZE MANIFOLD PRESSURE

INPUT RATING MAXIMUM INLET PRESSURES

PS360EWB placement

THIS APPLIANCE HAS BEEN CONVERTED ON _______________ TO ______________ GAS WITH KIT
NO. ________________ BY _______________ , WHO ACCEPTS THE RESPONSIBILITY FOR
THE CORRECTNESS OF THIS CONVERSION.

MODEL NO. MAIN BURNER ORIFICE SIZE MANIFOLD PRESSURE

INPUT RATING MAXIMUM INLET PRESSURES

PS360WB70 placement

Page 4 of 4 P. Jan. 98 Rev B p/n 36862

138
 SECTION 3 - SERVICING COMPONENTS

Appendix - Equivalent Orifice Sizes at High Altitudes

(Includes 4% reduction for each 1000 ft. above sea level), 4/02

139
SECTION 3 - SERVICING COMPONENTS
XI. ELECTRIC OVEN HEATING SYSTEM 2. Part number reference
A. PS200-series ovens Part No. Description
1. Description of heating system 27375-0001 Heating element, 208V
All PS200-series electric ovens use an on-off system 27375-0002 Heating element, 240V
for heater activation. When the oven demands heat, 27375-0003 Heating element, 380V
the temperature controller activates contactors that in
turn activate the heaters at 100% power. The contactors 28041-0015 Mercury contactor, 3 pole, 50A
open when the temperature rises to 2 degrees above 42810-0091 Contactor tube replacement kit (inc.
the set point, and close when the oven’s temperature qty. 1 retainer clip P/N 27170-0248)
falls 2 degrees Fahrenheit below the set point. Be- 42810-0090 Coil replacement kit (inc. qty. 3 re-
cause of residual heat within the oven, however, the tainer clip P/N 27170-0248)
temperature swing after preheating is about 5 degrees
28150-0130 Fuse, 50A, class T
Fahrenheit above and below the set point.
31463 Relay, solid state, 75A
IMPORTANT: Because the PS200-series elec- 35018 Circuit breaker block, 50A, 3 pole
tric oven uses an on-off system for heater acti-
vation, the temperature controller MUST be
3. Supply
set to the on-off operating mode. Refer to Tem-
perature Controller on Page 30. Ovens have a 208V, 220-240V, 380V, 416V or 480VAC
electrical supply. The control current of the oven oper-
Early PS200-series ovens used mercury contactors. ates at 110V, single phase. If the oven was specified
208-380V ovens used two 3-pole contactors. 416-480V for a 3 wire system, it was supplied with an optional
ovens used a single 3-pole contactor. Six 50A fuses control transformer to step the 3 phase current down
(one per element) protect the heating circuit. See Fig- for the control circuit. If the oven was specified for a 4
ure 76. wire system, the 4th (neutral) wire is utilized to split 2
of the 3 incoming 3 phase legs and obtain a separate
Current PS200-series ovens replace the mercury
110V circuit. Most export ovens are supplied with a
contactors with solid state relays mounted on heat
stepdown transformer for the 110V control voltage.
sinks. Six relays are used on 208-380V ovens. 416-
480V ovens use three relays. Ovens that use the solid
state relays also use 50A circuit breaker blocks in place
of the fuses. See Figure 77. Figure 77
NOTE: All control wire used on these ovens is PS200 electric (current) with solid state
rated at 221°F/105°C. DO NOT replace with lower relays and circuit breaker blocks
rated wire.
Figure 76
PS200 electric (early) with mercury
contactors and fuses

Mercury
contactor Circuit breaker
block with 50A
Terminal breakers
block

Solid state
relay

Fuseblock
with 50A
fuses

140
 SECTION 3 - SERVICING COMPONENTS
4. Heater specifications It is also possible to check for an open element using
• PS200-series electric ovens use six individual heat- an ampmeter. Any current through the element indi-
ing elements. cates that the element is not open.
• 208V elements are used for ovens with a 208V 6. Changing Heating Elements
supply.
NOTE: Wires going from the mercury contactor (or
• 240 volt elements are used for ovens with a 220, 230 solid state relays, as appropriate) to the heating ele-
or 240V supply. 240V elements are also used on ments are rated at #12 gauge TAGT, 482°F/250°C. DO
ovens with a 416V or 480V supply (connected in se- NOT, under any circumstances, use a wire of lesser
ries). rating or quality.
• 380V elements are used for ovens with a 380V NOTE: All lugs and connections are rated at 600°F/
supply. 316°C. All heating element connections are double-
• All heaters are connected in Delta. nutted.
• Each heating element is stainless clad and has a To remove the element:
3”/76mm cold (unheated) end next to the connect- • Remove the blower belt.
ing leg.
• Remove the 12 electrical lead connections to the
• Individual element electrical data heaters at the back wall.
Volts Watts Ohms Connection
• Remove the 12 bolts that hold the rear oven panel
208V 4500W 9.6W Parallel to the body. Once removed, DO NOT lay the panel
220V 3781W 12.8W Parallel on either its front or back side. This can damage
230V 4133W 12.8W Parallel the heating elements and blower fan. The panel
240V 4500W 12.8W Parallel should be kept upright as shown in Figure 78.
380V 4500W 32.2W Parallel • Remove the fan shroud.
416V 3380W 12.8W Series • Remove the screws at both ends of the element
480V 4500W 12.8W Series and pull the element straight out. See Figure 79.
5. Checking the Heating Elements • When replacing the rear oven panel, be sure to use
a high-temperature never-seize lubricant on the 12
The most common problems encountered with electric
bolts that hold the panel in place.
heaters are:
• Open or bad connections.
• Open, shorted or grounded heating elements.
To troubleshoot the heating elements, disconnect all
leads at the back wall and check each element with a
digital multimeter set to Ohms (W). Correct ratings are
shown in the table in the preceding section. Zero read-
ing on the ohm scale indicates an open or shorted ele- Figure 79
ment.
Figure 78 Removing elements
Fan shroud removed

Mounting
screws

141
SECTION 3 - SERVICING COMPONENTS
B. PS310/360-series ovens 2. Part number reference
1. Description of heating system Part No. Description
All PS310/360-series electric ovens use an on-off sys- 27374-0001 Heating element, 208V
tem for heater activation. When the oven demands 27374-0002 Heating element, 240V
heat, the temperature controller activates mercury
contactors that in turn activate the heaters at 100% 27374-0003 Heating element, 380V
power. The contactors open when the temperature rises 28041-0016 Mercury contactor, 3 pole, 30A
to 2 degrees above the set point, and close when the 27170-0251 Contactor tube replacement kit
oven’s temperature falls 2 degrees Fahrenheit below
27170-0250 Coil replacement kit
the set point. Because of residual heat within the oven,
however, the temperature swing after preheating is about 28154-0002 Fuse, 30A, class M (early)
5 degrees Fahrenheit above and below the set point. 28150-0134 Fuse, 40A, class T (current)
27021-0016 Fuse block, 40A (used when upgrading
IMPORTANT: Because the PS310/360-series
from 30A to 40A fuse - qty. 3 reqd.)
electric oven uses an on-off system for heater
activation, the temperature controller MUST
be set to the on-off operating mode. Refer to
3. Supply
Temperature Controller on Page 30.
Ovens have a 208V, 220-240V, 380V, 416V or 480VAC
Each bank of heaters (3 total) uses one mercury electrical supply. The control current of the oven oper-
contactor and three fuses. 30A fuses were used ates at 110V, single phase. If the oven was specified
through 1/91. Heat inside the machinery compartment for a 3 wire system, it was supplied with an optional
can de-rate these fuses, causing the fuse to blow pre- control transformer to step the 3 phase current down
maturely. To correct this situation, 40A fuses were used for the control circuit. If the oven was specified for a 4
2/91 and later. wire system, the 4th (neutral) wire is utilized to split 2
NOTE: All control wire used on this oven is AWM rated of the 3 incoming 3 phase legs and obtain a separate
at 221°F/105°C. DO NOT replace with lower rated wire. 110V circuit.

Figure 80 Figure 81
Removing the element bank mounting bolts Electrical leads disconnected

142
 SECTION 3 - SERVICING COMPONENTS
4. Heater specifications Ohms (W). Correct ratings are shown in the table in
• PS310/360-series electric ovens use 18 heating the preceding section. Zero reading on the ohm scale
elements in 3 banks (6 elements per bank). indicates an open or shorted element.
• 208V elements are used for ovens with a 208V It is also possible to check for an open element using
supply. an ampmeter. Any current through the element indi-
cates that the element is not open.
• 240 volt elements are used for ovens with a 220, 230
or 240V supply. 240V elements are also used on 6. Changing Heating Elements
ovens with a 416V or 480V supply (connected in se-
NOTE: Wires going from the mercury contactors to
ries).
the heating elements are rated at #12 gauge TAGT,
• 380V elements are used for ovens with a 380V 482°F/250°C. DO NOT, under any circumstances, use
supply. a wire of lesser rating or quality.
• All heaters are connected in Delta. NOTE: All lugs and connections are rated at 600°F/
• Each element is stainless-clad and has a 4-7/8”/ 316°C. All heating elements are double-nutted. The
124mm cold (unheated) end next to the connect- rear of each heating element is held to other elements
ing leg. by a spacer bracket. The only way the element can be
• Individual element electrical data changed is by removing the entire bank from the oven.
Volts Watts Ohms Connection To remove the element bank:
208V 1350W 32W Parallel 1. Remove the 4 bolts holding the bank of element to
220V 1134W 42.7W Parallel the oven. See Figure 80.
230V 1239W 42.7W Parallel 2. Remove the 9 electrical leads going to the element
240V 1350W 42.7W Parallel bank. See Figure 81.
380V 1350W 107W Parallel 3. Gently work the bank of elements out of the oven.
416V 1013W 42.7W Series Be careful not to pinch the wires between the frame
480V 1350W 42.7W Series of the oven and the side plate of the heating ele-
ments. See Figure 82.
5. Checking the Heating Elements 4. Remove the bank of elements and place them on
The most common problems encountered with electric the floor. The entire bank may now be serviced.
heaters are: 5. Remove the element jumper wires and element cover
• Open or bad connections. if individual elements need replacement.
• Open, shorted or grounded heating elements. NOTE: The spacer brackets MUST be reinstalled be-
To troubleshoot the heating elements, disconnect all fore assembling the element bank back into the oven.
leads from ALL of the elements in the bank. Then, These brackets keep the elements from touching each
check each element with a digital multimeter set to other during use. See Figure 82.

Figure 82
Element bank removed - spacer bracket visible
Spacer
brackets

143
SECTION 3 - SERVICING COMPONENTS
C. PS555 ovens 3. Supply
1. Description of heating system Ovens have a 208V, 220-240V, 380V or 480VAC elec-
All PS555 electric ovens use a variable pulse system trical supply. The control current of the oven operates
for heater activation. at 208/240V.
In response to the millivolt signal from the thermocouple, 208V and 240V ovens use a 3-wire system (4-wire in-
the temperature controller sends a 4-20mA signal to a cluding the ground connection). The control circuit op-
controller module. This module contains an amplifer erates at line voltage.
board and two solid state relays. The amplifier board 380V and 480V ovens use a 4-wire system (5-wire in-
receives the 4-20mA signal and in turn activates the cluding the ground connection). The 4th (neutral) wire
relays. The relays then activate the heating elements. is utilized to split the incoming 3 phase legs and obtain
The relays operate on a fixed cycle time. Within each a separate control circuit at 208/240V.
cycle, the relays activate the heating elements at 100%
4. Heater specifications
for a length of time that is proportional to the signal
from the amplifier board. • PS555 electric ovens use 12 heating elements in 4
assemblies (3 elements per assembly). Elements
When the oven is switched on, heat demand is at its
CANNOT be removed from the assembly. If one
peak and the elements are activated for 100% of each
element is not functioning properly, the entire as-
cycle. As the oven’s temperature approaches the set
sembly should be replaced.
point, the relays reduce the length of time that the heat-
ers are activated wihin each cycle. After the oven is • 208V elements are used for ovens with a 208V supply.
fully preheated, the heaters are usually activated for • 240 volt elements are used for ovens with a 220V,
about 30% of each cycle. This system allows the ac- 230V or 240V supply.
tual oven temperature can remain constant, with NO
• 380V elements are used for ovens with a 380V supply.
temperature swing.
• 480V elements are used for ovens with a 416V or 480V
IMPORTANT: The PS555 electric oven uses a supply.
variable pulse system that is designed to emu- • All heaters are connected in Delta.
late the PID gas operating mode. Because of • Heaters are grouped into four assemblies, each of
this, the temperature controller MUST be set which contains three elements. Elements CAN-
to the PID operating mode. NOT be removed from the assembly.
Temperature controller P/N 46837 (inc. with • Each element has a cold (unheated) end next to
Service Kit 47321) includes a dedicated vari- the connecting leg. 12”/0.3m leads are connected
able pulse mode intended for the PS536 elec- to the cold ends for easy connection to the termi-
tric oven. This mode is NOT used on the PS555 nal blocks on the back wall of the oven.
electric oven. If you are using controller P/N
46837, be sure to set the controller for the PID • Individual element electrical data
operating mode. Volts Watts Ohms Connection
208V 2667W 16.2W Parallel
Refer to Temperature Controller on Page 30.
220V 2241W 21.6W Parallel
Heaters are arranged into four assemblies, each of 230V 2449W 21.6W Parallel
which contains three elements. Each pair of assem- 240V 2667W 21.6W Parallel
blies (left and right) share a controller and a 50A circuit 380V 2667W 54.1W Parallel
breaker block. 416V 2003W 86.4W Parallel
NOTE: All control wire used on this oven is AWM rated 480V 2667W 86.4W Parallel
at 221°F/105°C. DO NOT replace with lower rated wire.
5. Checking the Heating Elements
2. Part number reference
The most common problems encountered with electric
Part No. Description heaters are:
43337 Heating element assembly, 208V • Open or bad connections.
44525 Heating element assembly, 230V • Open, shorted or grounded heating elements.
44526 Heating element assembly, 380V To troubleshoot the heating elements, disconnect all
44527 Heating element assembly, 480V leads at the terminal blocks on the back wall. Then,
check each element with a digital multimeter set to
44914 Controller module, 208/230/240V ovens
Ohms (W). Correct ratings are shown in the table in
44568 Controller module, 380/480V ovens the preceding section. Zero reading on the ohm scale
35018 Circuit breaker block, 50A, 3 pole indicates an open or shorted element.
144
 SECTION 3 - SERVICING COMPONENTS
It is also possible to check for an open element using • Disconnect the electrical lead connections from the
an ampmeter. Any current through the element indi- front of the oven to the remote terminal blocks on
cates that the element is not open. the back wall. Then, disconnect the leads from
the remote terminal blocks to the elements.
6. Changing Heating Elements • Remove the 8 hex bolts that hold the rear wall panel
NOTE: Wires going from the controller assembly to the body of the oven. Once removed, DO NOT
contactor to the heating elements are rated at 392°F/ lay the panel on either its front or back side. This
200°C. DO NOT, under any circumstances, use a wire can damage the heating elements, blower fan and
of lesser rating or quality. bearings. The panel should be kept upright.
To remove the element: • Remove the two hex head screws that hold the
element assembly to the back wall.
• Remove the blower belt on the affected side of the
oven. • When replacing the rear oven panel, be sure to use
a high-temperature never-seize lubricant on the 8
• Remove the wireway cover. hex bolts that hold the panel in place.

Figure 83
PS555 electric oven heating element removal

Lock Remote
washer terminal blocks

Flat
Hex
washer
bolt

Hex head
screw
Hex head
screw
Flat
Heating
washer
Wireway element
cover assembly

145
SECTION 3 - SERVICING COMPONENTS
D. Mercury Contactor Replacement Figure 84
Early PS200-series electric ovens and all PS310/360-se-
ries electric ovens use mercury contactors to activate the
heating elements. Each pole in the contactor is a separate
mercury-filled tube that is individually replaceable. This
feature ensures that the entire contactor should never have
to be replaced.
Individual part numbers for the mercury contactor compo-
nents are listed in the Part Number Reference sections on
Pages 140 and 142, respectively.
1. PS200-series mercury contactor replacement
• Remove the complete contactor from the oven.
Then, remove the terminal clamps from the
contactor tube(s) to be replaced.

Figure 85
• Locate the Tinnerman clips on the bottom side of
the contactor that hold each individual contact tube
in place.
• Find the break in the tube bracket located in the
center. Then, using a diagonal cutter, cut the
Tinnerman clip so that it may be removed.

Figure 86
• Remove the contact tube. If the coil must be re-
placed, all three contactor tubes must first be re-
moved.
• To replace the contactor tube(s), slide the thin end
of the tube into the contactor bracket.

146
 SECTION 3 - SERVICING COMPONENTS
• Support the wide end of the tube between two Figure 87
pieces of wood so that the terminal end will not be
damaged.

Figure 88
• Place a deep well socket over the new Tinnerman
clip.

Figure 89
• Gently tap the socket with a hammer to push the
clip down and into place.
NOTE: When replacing the mercury contactor into
the oven, the wider tube ends must be pointing UP.
The tubes must ALWAYS be mounted in a vertical
position.

147
SECTION 3 - SERVICING COMPONENTS
2. PS310/360-series contactor replacement Figure 90
• Remove the two Phillips-head screws holding the
cover in place. Then, remove the cover.

Figure 91
• Remove the six terminal lug screws. This proce-
dure must be followed when replacing the coil or
any one contact tube.
• The coil and contact tubes will now pull straight
out from the base. The coil or any individual con-
tact tube can now be replaced.
NOTE: When replacing the mercury contactor into
the oven, the wider tube ends must be pointing UP.
The tubes must ALWAYS be mounted in a vertical
position.

Figure 92
• Replace the cover and attach it with the two Phillips-
head screws. Note that the cover and base are
marked to show correct orientation.

148
 SECTION 4 - ELECTRICAL WIRING DIAGRAMS

SECTION 4
ELECTRICAL WIRING DIAGRAMS
I. COMPONENT WIRING
A. Temperature Controllers

149
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
B. Ignition Modules

150
 II. PS200-SERIES OVENS
151

SECTION 4 - ELECTRICAL WIRING DIAGRAMS

PS200-series gas oven (with solenoid valve and analog temp control), 208/240V main blower motor, 120V control circuit
208/240V, 50/60 Hz, 1 Ph, 3 pole, 4 wire supply (2 hot, 1 neutral, 1 ground)
 SECTION 4 - ELECTRICAL WIRING DIAGRAMS
152

PS200-series gas oven (with solenoid valve and digital temp control), 208/240V main blower motor, 120V control circuit
208/240V, 50/60 Hz, 1 Ph, 3 pole, 4 wire supply (2 hot, 1 neutral, 1 ground)
153

SECTION 4 - ELECTRICAL WIRING DIAGRAMS

PS200-series gas oven (with modulating valve), 208/240V main blower motor and control circuit
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply (2 hot, 1 ground)
 SECTION 4 - ELECTRICAL WIRING DIAGRAMS
154

PS200R68-series gas oven (with solenoid valve), 208/240V main blower motor, 120V control circuit
208/240V, 50/60 Hz, 1 Ph, 3 pole, 4 wire supply (2 hot, 1 neutral, 1 ground)
155

SECTION 4 - ELECTRICAL WIRING DIAGRAMS

PAGE 1 OF 2
PS200R68-series gas oven (with modulating valve), 208/240V main blower motor and control circuit
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply (2 hot, 1 ground)
 SECTION 4 - ELECTRICAL WIRING DIAGRAMS
156

PAGE 2 OF 2
PS200R68-series gas oven (with modulating valve), 208/240V main blower motor and control circuit
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply (2 hot, 1 ground)
157

SECTION 4 - ELECTRICAL WIRING DIAGRAMS

PS200VL-series gas oven (with analog temp control 34983), 208/240V main blower motor, 120V control circuit
208/240V, 50/60 Hz, 1 Ph, 3 pole, 4 wire supply (2 hot, 1 neutral, 1 ground)
 SECTION 4 - ELECTRICAL WIRING DIAGRAMS
158

PS200-series electric oven (USA version), 208/240V main blower motor and heating elements, 120V control circuit
208/240V, 50/60 Hz, 3 Ph, 4 pole, 5 wire supply (3 hot, 1 neutral, 1 ground)
159

SECTION 4 - ELECTRICAL WIRING DIAGRAMS

PS200-series electric oven (export 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)
 III. PS360-SERIES OVENS
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
160

PS310/314/360/360WB gas oven (with analog temp control), 208/240V main blower motor, 120V control circuit
208/240V, 50/60 Hz, 1 Ph, 3 pole, 4 wire supply (2 hot, 1 neutral, 1 ground)
161

SECTION 4 - ELECTRICAL WIRING DIAGRAMS

PS310/314/360/360WB gas oven (with digital temp control), 208/240V main blower motor, 120V control circuit
208/240V, 50/60 Hz, 1 Ph, 3 pole, 4 wire supply (2 hot, 1 neutral, 1 ground)
 SECTION 4 - ELECTRICAL WIRING DIAGRAMS
162

PS360WB70 gas oven (with Midco burner and solenoid valve), 208/240V main blower motor and control circuit
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply (2 hot, 1 ground)
163

SECTION 4 - ELECTRICAL WIRING DIAGRAMS

PS360EWB gas oven (with Midco burner and early temp control 32571), 208/240V main blower motor and control circuit
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply (2 hot, 1 ground)
 SECTION 4 - ELECTRICAL WIRING DIAGRAMS
164

PS360EWB gas oven (with Wayne burner and temp control 36056 or 46837), 208/240V main blower motor and control circuit
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply (2 hot, 1 ground)
165

SECTION 4 - ELECTRICAL WIRING DIAGRAMS

PS360-series electric oven, 208/240V main blower motor and heating elements, 120V control circuit
208/240V, 50/60 Hz, 3 Ph, 4 pole, 5 wire supply (3 hot, 1 neutral, 1 ground)
 III. PS555/570-SERIES OVENS
SECTION 4 - ELECTRICAL WIRING DIAGRAMS
166

PS570 or PS570S gas oven (with solenoid valve and analog temp control), 208/240V main blower motor, 120V control circuit
208/240V, 50/60 Hz, 1 Ph, 3 pole, 4 wire supply (2 hot, 1 neutral, 1 ground)
167

SECTION 4 - ELECTRICAL WIRING DIAGRAMS

PS570 or PS570S gas oven (with solenoid valve and digital temp control), 208/240V main blower motor, 120V control circuit
208/240V, 50/60 Hz, 1 Ph, 3 pole, 4 wire supply (2 hot, 1 neutral, 1 ground)
 SECTION 4 - ELECTRICAL WIRING DIAGRAMS
168

PS570S gas oven (with modulating valve), 208/240V main blower motor, 120V control circuit
208/240V, 50/60 Hz, 1 Ph, 3 pole, 4 wire supply (2 hot, 1 neutral, 1 ground)
169

SECTION 4 - ELECTRICAL WIRING DIAGRAMS

PS555 gas oven (early), 208/240V main blower motor and control circuit
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply (2 hot, 1 ground)
 SECTION 4 - ELECTRICAL WIRING DIAGRAMS
170

PS555G or PS570G gas oven, 208/240V main blower motor and control circuit
208/240V, 50/60 Hz, 1 Ph, 2 pole, 3 wire supply (2 hot, 1 ground)
171

SECTION 4 - ELECTRICAL WIRING DIAGRAMS

PS555 electric oven, 208/240V main blower motor, heating elements and control circuit
208/240V, 50/60 Hz, 3 Ph, 3 pole, 4 wire supply (3 hot, 1 ground)
SECTION 5 - REFERENCE

SECTION 5
REFERENCE

25-point preventative maintenance checklist

[ ] 1. Check and clean (blow out) machinery/control compartment.

[ ] 2. Check and clean (blow out) main blower motors.
[ ] 3. Check and clean (blow out and brush) axial fans.
[ ] 4. Check burner blower motor and fan operation.
[ ] 5. Check and clean igniter assembly.
[ ] 6. Check and clean all orifices.
[ ] 7. Install pilot tee if oven is not so equipped.
[ ] 8. Check gas pressures; adjust as necessary.
[ ] 9. Check air-fuel mixture; adjust as necessary.
[ ] 10. Check ignition cable for signs of deterioration.
[ ] 11. Check and tighten all electrical connections.
[ ] 12. Inspect conveyor belt for damage; repair as necessary.
[ ] 13. Inspect conveyor frame pivot plates.
[ ] 14. Inspect conveyor shaft bushings - Replace drive side bushing.
[ ] 15. Check conveyor drive chain tension; adjust as necessary.
[ ] 16. Verify proper air finger arrangement; correct as required.
[ ] 17. Inspect and clean (vacuum) conveyor motor and motor brushes.
[ ] 18. Inspect conveyor motor sensor and magnet; verify correct spacing; adjust as necessary.
[ ] 19. Check conveyor speed control; verify belt speed to be within 10 seconds of set point.
[ ] 20. Verify that proper number of thermocouples are installed.
[ ] 21. Check temperature control with thermocouple source to verify accuracy.
[ ] 22. Check high limit safety circuit with thermocouple source to verify correct operation.
[ ] 23. Check cool down feature with thermocouple source to verify correct operation.
[ ] 24. Using the “read” function of the temperature controller, verify and record the high ambient reading.
[ ] 25. Verify positive ignition on cold start.

172
 SECTION 5 - REFERENCE

Fractional inches to decimal and millimeter equivalents

Decimal equivalents of drill sizes

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SECTION 5 - REFERENCE

General conversion factors

MULTIPLY BY TO OBTAIN MULTIPLY BY TO OBTAIN MULTIPLY BY TO OBTAIN
atmospheres (std. - feet/min ............................. 0.5080 ..... cm/sec. meters ................................. 100 ........ centimeters
760mm of mercury feet/min ............................ 0.01667 .... ft./sec. meters ................................ 1000 ....... millimeters
at 32°F/0°C) ...................... 14.696 ..... lbs./sq. inch feet/min ............................ 0.01829 .... km/hr. meters ................................ 3.281 ...... feet
atmospheres ........................ 76.0 ....... cm of mercury feet/min ............................. 0.3048 ..... meters/min. meters ................................ 39.37 ...... inches
atmospheres ....................... 29.92 ...... in. of mercury feet/min ............................ 0.01136 ..... miles/hr. (mph) meters ................................ 1.094 ...... yards
atmospheres ....................... 33.90 ...... ft. of water foot-pounds ...................... 0.001286 ... BTU ounces (fluid ....................... 1.805 ...... cubic inches
atmospheres ...................... 1.0333 ..... kg/sq. cm ounces (fluid ..................... 0.02957 .... liters
atmospheres ....................... 14.70 ...... lbs./sq. inch gallons (imp.) ..................... 1.201 ...... gallons (U.S.)
atmospheres ....................... 1.058 ...... tons/sq. ft. gallons (U.S.) ..................... 0.833 ...... gallons (imp.) ounces/sq. in. ................... 0.0625 ..... lbs./sq. in. (psi)
gallons (U.S.) ..................... 3785 ....... cubic cm ounces/sq. in. ..................... 1.73 ....... inches of water
BTU (British ....................... 0.2520 ..... kilogram-calories
Thermal Units) gallons (U.S.) .................... 0.1337 ..... cubic feet pints .................................. 0.4732 ..... liter
BTU .................................... 777.5 ...... ft.-lbs. gallons (U.S.) ...................... 231 ........ cubic inches pounds ................................. 16 ......... ounces
BTU ................................. 0.000393 ... horsepower-hrs. gallons (U.S.) ...................... 128 ........ fluid ounces
gallons (U.S.) ..................... 3.785 ...... liters pounds of water ................ 0.01602 .... cubic ft.
BTU .................................... 0.293 ...... Watt-hrs. pounds of water .................. 27.68 ...... cubic in.
BTU/min ............................. 12.96 ...... ft.-lbs.-sec. gallons (U.S.) water ............. 8.35 ....... lbs. H 2 O@60°F/16°C pounds of water ................. 0.1198 ..... gallons
BTU/min ........................... 0.02356 .... horsepower horsepower ......................... 42.44 ...... BTU/min. pounds/sq. ft. ................... 0.01602 .... feet of water
BTU/min ........................... 0.01757 .... kilowatts horsepower ........................ 33,000 ..... foot-lbs./min. pounds/sq. ft. .................. 0.006945 ... lbs./sq. in. (psi)
BTU/min ............................. 17.57 ...... Watts horsepower .......................... 550 ........ foot-lbs./sec.
horsepower ........................ 0.7457 ..... kilowatts pounds/sq. in. .................. 0.06804 .... atmospheres
calories ........................... 0.003968 ... BTU pounds/sq. in. .................... 2.307 ...... feet of water
horsepower ......................... 745.7 ...... Watts
centimeters ........................ 0.3937 ..... inches pounds/sq. in. .................... 2.036 ...... in. of mercury
centimeters ....................... 0.03280 .... feet horsepower (boiler) ............ 33,479 ..... BTU/hr. pounds/sq. in. .................... 27.68 ...... inches of water
centimeters .......................... 0.01 ....... meters horsepower (boiler) ............. 9.803 ...... kilowatts
temp. (°C)+273 ...................... 1 .......... absolute temp (°K)
centimeters ........................... 10 ......... millimeters horsepower-hours. .............. 2547 ....... BTU temp. (°C.)+17.78 ................. 1.8 ........ temperature (°F)
cm of mercury ................... 0.01316 .... atmospheres horsepower-hours .............. 0.7457 ..... kilowatt-hours temp. (°F)+460 ...................... 1 .......... absolute temp.
cm of mercury .................... 0.4461 ..... ft. of water inches ................................. 2.54 ....... centimeters temp. (°F.)-32 ....................... 5/9 ........ temperature (°C)
cm of mercury ..................... 136.0 ...... kg/sq. meter inches ................................. 25.4 ....... millimeters therm ................................ 100,000 .... BTU
cm of mercury ..................... 27.85 ...... lbs./sq. ft. inches ............................... 0.0254 ..... meters
cm of mercury .................... 0.1934 ..... lbs./sq. in. (psi) inches ............................... 0.0833 ..... feet ton, refrigeration ................. 12,000 ..... BTU/hr.
tons (long) .......................... 2240 ....... pounds
cubic feet ....................... 2.832x104 ... cubic cm inches of mercury ............. 0.03342 .... atmospheres tons (short) .......................... 2000 ....... pounds
cubic feet ........................... 1728 ....... cubic inches inches of mercury ............... 1.133 ...... feet of water
cubic feet ......................... 0.02832 .... cubic meters inches of mercury ............... 13.57 ...... inches of water watts .................................. 3.415 ...... BTU
cubic feet ......................... 0.03704 .... cubic yards inches of mercury ............... 70.73 ...... lbs./sq. ft. watts ................................ 0.05692 .... BTU/min.
cubic feet ......................... 7.48052 .... gallons (U.S.) inches of mercury .............. 0.4912 ..... lbs./sq. in. (psi) watts .................................. 44.26 ...... foot-pounds/min.
watts ................................. 0.7376 ..... foot-pounds/sec.
cubic ft./min. ....................... 472 ........ cubic cm/sec. inches of water ............... 0.002458 ... atmospheres watts ............................... 0.001341 ... horsepower
cubic ft./min. ..................... 0.1247 ..... gallons/sec. inches of water ................ 0.07355 .... in. of mercury watts .................................. 0.001 ...... kilowatts
cubic ft./water .................... 62.4. ....... lb. @ 60°F/16°C inches of water ................. 0.5781 ..... oz./sq. inch
inches of water .................. 5.202 ...... lbs./sq. ft. watt-hours .......................... 3.415 ...... BTU/hr.
feet ..................................... 30.48 ...... centimeters watt-hours .......................... 2655 ....... foot-pounds
feet ....................................... 12 ......... inches inches of water ................ 0.03613 .... lbs./sq. in. (psi)
watt-hours ....................... 0.001341 ... horsepower hrs.
feet .................................... 0.3048 ..... meters kilowatts ............................ 56.92 ...... BTU/min. watt-hours .......................... 0.001 ...... kilowatt-hours
feet ....................................... 1/3 ........ yards kilowatts ............................ 1.341 ...... horsepower
feet of water ...................... 0.02950 .... atmospheres kilowatts ............................ 1000 ....... Watts
feet of water ....................... 0.8826 ..... in. of mercury kilowatt-hours .................... 3415 ....... BTU
feet of water ...................... 0.03048 .... kg/sq. cm liters .................................. 0.2642 ..... gallons
feet of water ........................ 62.43 ...... lbs./sq. ft. liters ................................... 2.113 ....... pints (liquid)
feet of water ....................... 0.4335 ..... lbs./sq. in. (psi) liters ................................... 1.057 ...... quarts (liquid)

Pressure conversions
in. H2O in. Hg mbar psi oz./sq. in. in. H2O in. Hg mbar psi oz./sq. in.
0.10 0.007 0.20 0.0036 0.0577 8.00 0.588 20.0 0.289 4.62
0.20 0.015 0.50 0.0072 0.115 9.00 0.662 22.4 0.325 5.20
0.30 0.022 0.75 0.0108 0.173 10.00 0.74 25.0 0.361 5.77
0.40 0.029 0.98 0.0145 0.231 11.00 0.81 27.4 0.397 6.34
0.50 0.037 1.25 0.0181 0.289 12.00 0.88 29.8 0.433 6.92
0.60 0.044 1.50 0.0217 0.346 13.00 0.96 32.5 0.469 7.50
0.70 0.051 1.72 0.0253 0.404 13.60 1.00 33.8 0.491 7.80
0.80 0.059 1.98 0.0289 0.462 13.90 1.02 34.5 0.500 6.00
0.90 0.066 2.23 0.325 0.520 14.00 1.06 35.8 0.505 8.08
1.00 0.074 2.50 0.036 0.577 15.00 1.10 37.2 0.542 8.7
1.36 0.100 3.38 0.049 0.785 16.00 1.18 40.0 0.578 9.2
1.74 0.128 4.33 0.067 1.00 17.00 1.25 42.3 0.614 9.8
2.00 0.147 4.97 0.072 1.15 18.00 1.33 45.0 0.650 10.4
2.77 0.203 6.87 0.100 1.60 19.00 1.40 47.4 0.686 10.9
3.00 0.221 7.48 0.109 1.73 20.00 1.47 49.7 0.722 11.5
4.00 0.294 9.95 0.144 2.31 25.00 1.84 62.3 0.903 14.4
5.00 0.368 12.4 0.181 2.89 27.20 2.00 67.7 0.975 15.7
6.00 0.442 14.9 0.217 3.46 27.70 2.03 68.7 1.00 16.0
7.00 0.515 17.4 0.253 4.04

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Pressure conversion chart

To use this chart, simply place a straightedge so
that it intersects the known value and lies across
the center of the bullseye. Readings on all scales
will then be equivalent.

Ohm’s Law equation wheel

Using this wheel, you can calculate any one of the
following four basic factors of electricity, as long
as two of the others are known:
• Power - Watts (W), shown as “W”
• Current - Amperes (A), shown as “A”
• Voltage - Volts (V), shown as “E”
• Resistance - Ohms (W), shown as “R”
Choose an equation that will give you the value
that you need based on what values are already
known.

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SECTION 5 - REFERENCE

Common electrical wiring diagram symbols

176
 SECTION 5 - REFERENCE

Common electrical wiring diagram symbols (continued)

177
SECTION 5 - REFERENCE

Common electrical wiring diagram symbols (continued)

178
 SECTION 5 - REFERENCE

Common electrical wiring diagram symbols (continued)

179
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We recognize and applaud CFESA’s ongoing efforts
to improve the quality of technical service in the industry.

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is a registered trademark of Middleby Marshall, Inc. All rights reserved.

Middleby Cooking Systems Group • 1400 Toastmaster Drive • Elgin, IL 60120 • (847) 741-3300 • FAX (847) 741-4406 • 24-Hour Service Hotline (800) 238-8444
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