Market Forge 3500M24SC Installation Manual

3500 & 3500 Power-Plus

OWNER’S MANUAL

WARNING:

Improper installation, adjustment, alteration,
service or maintenance can cause property
damage, injury or death. Read the installa­tion, operation and maintenance instructions
thoroughly before installing or servicing this
equipment.

FOR YOUR SAFETY:

Do not store or use gasoline or other am­mable vapors and liquids in the vicinity of
this or any other appliance.

Post in a prominent location, instructions to
be followed in the event the user smells gas.
This information shall be obtained by con­sulting the local gas supplier.

MODELS: □ 3500

□ 3500 Power-Plus

INSTALLATION, OPERATION, MAINTENANCE, SERVICE AND PARTS MANUAL

Tel: [phone] • Fax: [phone] • Toll Free: [phone] • Outside MA Fax: [phone]

FORM NO. S-4842 REV. D 04/14 Printed in U. S. A.

35 Garvey Street • Everett • MA 02149

E-mail: custserv@mi.com • Web site: www.mi.com

TABLE OF CONTENTS

INTRODUCTION

BASIC FUNCTIONING ........................................1

SERVICE .............................................................1

INSTALLATION

ASSEMBLY .........................................................2

SETTING IN PLACE ............................................2

MECHANICAL CONNECTIONS .........................2

WATER CONNECTIONS ....................................2

INSTALLATION CHECK-OUT .............................2

INITIAL CONTROL SETTINGS ...........................2

COOKER CHECK-OUT .......................................2

SHUT-DOWN PROCEDURE ..............................3

REVERSING THE DOORS .................................3

OPERATION

OPERATING CONTROLS AND INDICATORS ...3

OPERATING PROCEDURES .............................3

STEAM SOURCE OPERATING ..........................4

PREHEATING .....................................................4

COOKING ............................................................4

SHUT-DOWN PROCEDURE ..............................4

CLEANING ..........................................................4

DRAINAGE ..........................................................4

COOKING COMPARTMENT DRAINAGE ...........4

DRIP / SPILL TROUGH DRAINAGE ...................4

CONTROLS AND INDICATORS ........................5

DIGITAL TIMER ....................................................5A

FACTS ON PARADE ...........................................6

TIMER SETTINGS ..............................................7

PRINCIPLES OF OPERATION

GENERAL ............................................................9

PLUMBING CIRCUITS ........................................9

STEAM INLET LINE ............................................10

STEAM EXHAUST AND DRAIN LINES ..............10

STEAM EXHAUST CONDENSING SYSTEM .....10

ELECTRICAL CIRCUITS ....................................10

CONTROL CIRCUIT COMPONENTS .................10

PICTORIAL DIAGRAM OF STEAM AND

WATER .................................................................11

CIRCUITS ............................................................11

INDICATOR LIGHTS ...........................................11

BUZZER ..............................................................11

DOOR INTERLOCK SWITCH .............................11

THERMOSTATIC SWITCH .................................11

TROUBLE-SHOOTING

GENERAL ...........................................................12

GENERAL TROUBLE-SHOOTING GUIDE .........12

INCOMING POWER ............................................13

ELECTRIC INSPECTION ....................................13

60 MINUTE TIMER ..............................................13

TIMER CONTACTS .............................................13

ELECTRICAL FAULT ISOLATION GUIDE ..........13

WIRING AND SCHEMATIC DIAGRAM (FOR

MODEL 3500 ONLY) ...........................................14

WIRING AND SCHEMATIC DIAGRAM (FOR

MODEL POWER-PLUS ONLY) ............................15

TIMER MOTOR ...................................................16

DOOR INTERLOCK SWITCH .............................16

STEAM SOLENOID VALVES ..............................16

INDICATOR LIGHTS ...........................................16

COOKING COMPARTMENT THERMOSTATIC

SWITCH ..............................................................16

BUZZER ..............................................................17

COLD WATER CONDENSER CIRCUIT .............17

MAINTENANCE

GENERAL ...........................................................17

PREVENTIVE MAINTENANCE ...........................17

COOKING COMPARTMENT CLEANING ...........18

REPAIR AND REPLACEMENT ...........................18

DOOR LATCH TENSION ADJUSTMENT ...........18

ILLUSTRATED PARTS LIST

GENERAL ...........................................................18

ORDERING INFORMATION ...............................18

CABINET ASSEMBLY .........................................19

DOOR ASSEMBLY ..............................................21

CONTROL PANEL ASSEMBLY ...........................22

CONDENSER ASSEMBLY ..................................23

COMPLETE CONDENSER ASSEMBLY .............24

3500 POWER-PLUS ............................................25

i

INTRODUCTION

This service and parts manual contains general infor­mation, installation operation, principles of operation,
trouble-shooting, and maintenance information for
the Market Forge 3500 Pressureless Steam Cookers.
Also included is a parts list in which each replaceable
part is identied and shown in an accompanying ex­ploded view.

The 3500 is a pressureless steam cooker consist­ing of two independently controlled compartments
enclosed in a single cabinet. Each compartment is
equipped with a separate three-piece door with inner
gasket plate isolated from the exterior surface.

Door latches operate by action for positive sealing
of inner door. Steam and steam-condensing circuits
are electrically controlled. Operating controls are dis­played on a single front-mounted panel and include
separate timers with indicator lights for selection of
constant steam or 60 minute long duration cooking.

A separate steam source required for operation of the
Pressureless Cooker is normally purchased with it,
please refer to the respective manual for guidance.

BASIC FUNCTIONING:

The Model 3500 may be operated with only one
compartment in use; or both may be used simultane­ously. Each compartment is equipped with identical
controls, allowing selection of constant steam or 60
minute timer operation.

The cooker becomes operational when it is set to con­stant steam, or the timer is set at the desired cooking
time and the compartment door is closed. The indi­cator light comes on and the steam solenoid valve

opens, allowing steam to ow into the compartment.

At the end of the set interval, timer contacts switch
to shut off the cooking operation and sound a signal
buzzer. The buzzer is silenced by returning the timer
dial to the OFF position. In the constant steam mode,
operation will be continuous.

Steam emitted from the compartment along with liquid
cooking drainage is directed through a drain screen
inside the compartment into the cooker drain line.

A cold water solenoid valve connected into the cooker
drain line is automatically actuated by a thermostatic
switch in the boiler drain to condense the steam to
water prior to discharge into the boiler drain.

SERVICE:

Required service, both preventive and corrective, is
explained in Section 6. Should repairs be required, a
network of authorized agencies is available to assist
with prompt service.

A current Directory of Authorized Service Agencies
may be obtained by contacting:

Market Forge Industries Inc.

35 Garvey Street

Everett, Massachusetts 02149-4403

Telephone: [phone]

Toll Free: [phone]

Fax: [phone]

Outside MA Fax: [phone]

Parts / Price / Service Telephone: [phone]

custserv@mi.com

www.mi.com

The model and serial numbers must be referenced
when corresponding with Market Forge.

When steam owing inside the compartment has

raised the interior temperature to 195°F, the contacts
of a thermostatic switch automatically close, complet­ing the circuit to the timer motor and starting the cook­ing time period.

The data plate containing the serial number pertain­ing to the equipment is located on the lower front trim
of the cabinet.

1

INSTALLATION

ASSEMBLY:

The Pressureless Cooker is factory-mounted on a
cabinet base containing either a steam boiler or di­rect steam connection controls for the cooker. The
assembled unit is shipped bolted to a skid, with cabi­net feet in a separate container. Steps required for
assembly are as follows:

Remove the four bolts that fasten the equipment

1.
frame to the skid.

Install feet in threaded mounting locations of the

2.
cabinet frame.

Mount the two bafes on studs located on the right-

3.
inside of the cooking compartments.

Mount the four pan support racks in brackets inside

4.
control compartments.

Attach panels to lower cabinet. Detailed instruc-

5.
tions are enclosed with the panels.

Attach the drip trough on studs located on the face

6.
of the unit.

Equipment failure caused by inadequate water qual­ity is not covered under warranty.

CAUTION:

PVC or CPVC are not acceptable materials for drains.

INSTALLATION CHECK-OUT:

Check-out procedures for the cooker mounted on
steam boilers of electric, gas, and steam coil utility or
direct-connected steam are given in separate installa­tion instructions for each. If the cooker fails to perform
as described, consult the Trouble-Shooting Guide for
corrective action. If difculty arises with the boiler, ref­erence the separate service and parts manual for that
equipment.

Before making this check-out, the operator must be
thoroughly familiar with the operating procedures on
page 3 and with the function of each control described
in Table 1 on page 5. Reference Figure 1, also on
page 5 for identication of controls required in the fol­lowing procedures.

SETTING IN PLACE:

The location of installation must be under an exhaust
hood, which will remove small amounts of water va­por emitted when the cooker doors are opened, and
exhaust fumes from the air. Level the unit in nal loca­tion by turning the adjustable feet. Using the cabinet
top as a reference, obtain level adjustment left-to­right and front-to-back.

MECHANICAL CONNECTIONS:

Since the Pressureless Cooker is interconnected at
the factory to the steam boiler or direct steam plumb-

ing, no eld connections to the cooker are required.

All electrical and plumbing connections are routed to
the steam boiler cabinet through the 6 inch high space

between the oor and the bottom edge of the cabinet

frame. Connection locations for the cooker mounted
on steam boilers of electric, gas, and steam coil utility
and direct-connected steam are shown in separate
installation instructions for each.

WATER CONNECTIONS:

Before connecting water to this unit, have water sup­ply analyzed to make sure that hardness is no grater
than 2.0 grains per gallon and pH level is within the
range of 7.0–8.5. Water that fails to meet these stan­dards should be treated by the installation of a water
conditioner.

INITIAL CONTROL SETTINGS:

Before beginning the start-up procedures for the
cooker, the instruction plate and service manual for
the steam boiler must be consulted and all start-up
procedures completed to supply 15 PSI steam to the
steam inlet line for the cooker.

All steam boiler controls are in the operating mode

1.
and 15 PSI steam is applied to the cooker inlet
plumbing.

Cooker timers for both compartments (Figure 1,

2.
page 5) are in the OFF position.

Cooker compartments are empty of all information

3.
materials, pan supports are mounted in place, and
doors are open.

COOKER CHECK-OUT:

The cooker check-out procedures are as follows:

With the doors open set timers to about the “4 min-

1.

ute” position. Observe that indicator lights are off
and steam does not enter compartments.

Close cooker compartment doors. Observe that

2.

indicator lights turn on, and steam can be heard
rushing into the compartment simultaneously with
the door closing.

Observe the boiler drain line for passage of steam

3.

into the open oor drain. Correct steam condenser
operation is evidenced by presence of water ow-

2

INSTALLATION

ing from the drain line.

Observe cooker operation for several minutes. Op-

4.
eration is correct if timer dials begin to rotate after a
short delay period required for preheating. After the
delay period plus the “4 minute” initial setting, the
timer dials will return to the “0 minute” position, at
which a buzzer sounds. The buzzer is silenced by
turning the dial to the OFF position.

SHUT-DOWN PROCEDURE:

No shut-down procedure is required for the Pressure­less Cooker except to check that all timer dials (2) are
in the OFF position and the compartment doors are
open. Consult the steam boiler instruction plate and
complete the shut-down procedures for the boiler.

REVERSING THE DOORS:

The Pressureless Steam Cooker has a reversible
cooking compartment door. This section contains in­structions for reversing this door.

Open the cooking compartment door.

1.

Remove the two screws that attach the top hinge

2.

to the front of the unit.

Slide the door upward, off the bottom hinge.

3.

Remove the two screws that attach the bottom

4.

hinge to the front of the unit.

Remove the plastic hole plugs from the front of

5.

the unit. Push the black hole plugs into the left-up­per and -lower hinge mounting holes.

Reinstall the top hinge with spacers and screws

6.

into the right-lower hinge mounting hole.
Rotate the hinge 180° for installation, so that the
pin that the door rides on is now facing UP.

Remove the door latch assembly from the face

7.

of the unit. The two nuts mounting the door latch
are located behind the face of the unit and must
be accessed by removing the control panel. First
shut off the power to the unit at its source then

remove the control panel by unscrewing the eight
mounting screws and pulling the panel away from
the front frame.

Remove the two white hole plugs from the left

8.
door latch mounting holes, and insert them into
the right door latch mounting holes (where the
door latch assembly was originally mounted).

Rotate the door latch assembly 180°, and install

9.
into the left door latch mounting holes.

NOTE: Each stud on the latch assembly should
have a plastic washer, a spring, a plastic washer,
and a Nyloc type nut.

To adjust the tension of the door latch, tighten both

10.
nuts down until the springs are fully compressed,
then back each nut off 1/2 turn.

Replace the control panel, and reconnect the

11.
power to the unit.

Remove the inner door assembly by removing the

12.
six screws and spacers on the top and bottom of
the door.

Move the magnet and magnet clip to the opposite

13.

side of the inner door panel (see g. 5, page 20).

Put the door back together, making sure the mag-

14.
net is located at the top of the door, and refasten it
together with the six screws and spacers into the
top and bottom of the door.

Rotate the door 180° for mounting.

15.

Slide the remaining hinge into the top door bear-

16.
ing.

Slide the door and hinge assembly down onto the

17.
hinge that you have already mounted to the front
of the unit. Use the two to mount the top hinge into
the right upper hinge mounting holes.

NOTE: Be sure to include spacer washers behind
the hinges.

OPERATION

OPERATING CONTROLS AND INDICATORS:

The controls and indicators required to operate the
Pressureless Steam Cooker are listed in Table 1 on
page 5, together with a short functional description of
each. Figure 1 on page 5 shows the physical location
of each control and indicator.

OPERATING PROCEDURES:

The 3500 Pressureless Steam Cooker defrosts fro­zen foods and cooks fresh and defrosted foods. Each
cooking compartment permits selection of continuous
(constant steam) cooking or timed (0–60 minutes)
cooking. Instructions for operation are included in
this section. Consult Test Kitchen Bulletin for detailed
cooking information.

3

OPERATION

STEAM SOURCE OPERATION:

The Pressureless Cooker is supplied mounted on a
cabinet containing either a steam boiler or controls
for direct-connected steam. Manual controls are ac­cessed by opening the cabinet door. The start-up
procedure for the steam source is completed once
before each daily operating period of the cooker. (For
steam boilers, see instruction plate.)

PREHEATING:

Before each initial operation of the cooker, and at any
other time when the cooking compartment is cold, a
one minute preheating period is required. To preheat
the cooker, put steam source into operation and pro­ceed as follows:

Close cooking compartment door.

1.

2.

Set 60 Minute Timer Dial (1) to “one minute” set
ting.

NOTE:

Total elapsed preheating time equals the timer set­ting plus a short delay period needed to active a
thermostatic switch included in the controls.

Turn off buzzer, which sounds to indicate cooking

3.
is complete, by setting the Timer Dial (1) to OFF
position.

COOKING:

Before loading the cooker, be sure compartment is
hot. Refer to the preheating section above for pre­heating instructions.

Unload by sliding pans of food from pan supports,

7.
taking care to avoid hitting compartment opening.

CAUTION: SURFACES & OANS ARE HOT, USE
POT HOLDER TO REMOVE PANS.

SHUT-DOWN PROCEDURE:

No shut-down procedure is required for the cooker
except to check that both timer dials are in the OFF
position and that both compartment doors are open.
When all cooking has been completed for the day, the
steam source must be shut off. (For steam boilers,
see instruction plate.)

CAUTION:

When the unit is not in use, leave the cooking com­partment door slightly ajar to prolong the life of the
door gasket.

-

CLEANING:

After each period of daily operation (more frequent­ly as required to maintain cleanliness), the cooker
should be thoroughly cleaned by completing the fol­lowing steps:

Remove left- and right-side pan supports, bafes,

1.
and drain screens by lifting up and off mounting
studs. Wash with a mild detergent. Rinse and set
aside for reassembly.

Wash cooking compartment interior using a mild

2.
detergent and water. Rinse and dry thoroughly.

Replace pan supports, bafes, and drain screens

3.
in compartment and leave door open.

Slide pans of food into cooking compartment pan

1.
supports.

Close cooking compartment door.

2.

3.

Set timer cooking time:
a. Constant steam - for continuous cooking.
b. 60 minute timer - for timed cooking.

Set appropriate timer to the required cooking time

4.
(see page 6).

Turn off buzzer, which sounds to indicate cooking is

5.
complete, by setting timer dial to the OFF position.

Open door sightly at rst letting most of the steam

6.
out of the compartment and then fully open the
door.

DRAINAGE:
 COOKING COMPARTMENT DRAINAGE:

The bottom of the cooking compartment is angled
slightly toward the rear of the unit. This assures that
any condensate build-up or spills will be directed to­ward the drain hole, which is located at the rear bot­tom center of the cooking compartment. Any liquid
exiting the cooking compartment runs down the cook­ing compartment drain tube and into the drain line.

DRIP/SPILL TROUGH DRAINAGE:

The 3500 Pressureless Steam Cooker has a drip/spill
trough below the cooking compartment door. It will
catch any condensate gathering on the front of the
macine when the door is opened.

4

OPERATION

TABLE 1

CONTROLS & INDICATORS (Refer to Fig. 1)

ITEM DESCRIPTION FUNCTION

1 Timer/Constant Steam

2 Indicator Light (Red)

3 Buzzer (Not Shown) Signals end of cooking period.

Controls cooking up to 60 minutes for
uses constant operation.

Indicated when lit that the cooker is
in operation.

Fig. 1 Control Panel

5

OPERATION

DIGITAL CONTROL PANEL

NOTE:

USER PROGRAMING OF THE TIMER CYCLE IS EASILY ACCOMPLISHED
VIA A (12) BUTTON NUMERIC KEYPAD AND A (4) DIGIT NUMERIC LED
DISPLAY. CONTROL

START PROGRAMING:

FIRST: Make sure doors are shut on both compartments.

SECOND: Flip on POWER SWITCH, located in the middle of control panel
to the ON position.

THIRD: Press the CLEAR button and HOLD for two (2) seconds. This
should clear the timer display to 00:00.

THE TIMER IS NOW READY FOR PROGRAMING. The timers are program­mable from one second to 99 minutes and 99 seconds.

PLEASE NOTE: TIMER WILL NOT START COUNTING DOWN UNLESS:

1) DOOR IS SHUT.

2) THE THERMOSTAT REACHES 193oF INSIDE THE
COMPARTMENT.

When the timer reaches “0” the word “END” will  ash on the display. The

AUTO-ALARM will sound and continue until the START/STOP button is
pressed.

When you press STOP, the existing program remains in the system. It is nec­essary to press CLEAR, then RE-PROGRAM the new time as needed.

NOTE: To STOP the TIMER in MID-COUNT DOWN, PRESS and HOLD the
STOP button for a few seconds.

The word “PAUSE” will appear on the screen every time the door is opened.
When the door is closed, the timer will resume the count down.

FEATURES:

1) FOUR DIGIT DISPLAY – Example 00:00

2) AUTO ALERT = End of cycle sound.

3) “END” = Displayed at the end of cycle.

4) “PAUSE” = Displayed when doors are opened.

5) START/STOP = Control Button for start and stopping.

6) POWER SWITCH = Turn power ON and OFF.

Fig. 2 Digital Control Panel

NOTE: Unit is equipped with MANUAL OVERRIDE in the event of a TIMER
FAILURE (CONSTANT STEAM).

5A

OPERATION

TEST KITCHEN BULLETIN

MODEL 3500 PRESSURELESS COOKER FACTS ON PARADE

Frozen vegetables should always be cooked in perforated 12” x 20” x 2 1/2” pans 7 1/2 lbs (34 kg) maxi-

1.

mum per pan.

Frozen entrees should be underlined with a perforated pan for best results. If they are defrosted rst, the

2.

heating time will be decreased.

Fresh foods may also be cooked in this unit. Vegetables and other foods where the stock is not to be

3.

retained should be cooked in perforated 12” x 20” x 2 1/2” pans for the most nutritious results.

There is a thermostatic time delay built into this unit which adapts the unit to the proper cooking time. This

4.

means that the total time will usually be longer than the time setting.

There is a safety microswitch on the door which shuts off the steam each time the door is opened if the

5.

unit is in the cooking cycle.

Both compartments may be lled and timers set simultaneously.

6.

Total cooking time will vary depending on the load, even though the timer setting is the same.

7.

All foods, except cakes and pastry, can be cooked in a steam cooking unit.

8.

Steam cooked meals have greater nutritional value since they retain most of their vitamins and minerals.

9.

Because foods are cooked faster by the higher temperatures of steam cooking, they can be prepared

10.

closer to serving time, insuring maximum freshness.

Steam cooked foods have a higher percent yield more portions per dollar spent.

11.

Food may be served from the same pan in which it is steam cooked, thus reducing food breakage since

12.

there is no extra handling or transferring of food from cooking pans to serving pans. It also reduces pot
washing tasks.

Some important advantages of steam cooking are labor saving, reduced operating costs, space saving,

13.

and the lifting of heavy stock pots is eliminated.

Rice and spaghetti products, if thoroughly wet at the start of the cooking process, are very easily pre-

14.

pared.

Food such as potatoes, poultry, seafood, and some meats may be blanched in the steam cooker, thus

15.

reducing the total cooking time and grease absorption.

Fuel is used only when the steam cooking unit is in operation.

16.

The steam cooker will loosen foods burned on pans making washing easier.

17.

Solid pans are recommended when liquid is to be retained and perforated pans when the liquid is not to

18.

be retained.

Eggs may be cooked out of the shell if they are to be chopped which eliminates peeling after steaming.

19.

The steam cooker can be opened during the cooking period to add or remove items. If any time is lost,

20.

and adjustment may be make on the timer.

Steam cooking information, including recommended pan size and type, weight per pan, cooking times and

21.

pan yields are given on the following pages of this bulletin.

6