Market Forge F-25PE Service Manual
F-PE, F-LE AND FT-LE SERIES
2/3 JACKETED ELECTRIC STATIONARY & TILTING KETTLES
PARTS AND SERVICE MANUAL
EFFECTIVE APRIL 6, 2016
The Company reserves the right to make substitution in the event that items specied are not available.
ERRORS: Descriptive and/or typographic errors are subject to correction.
Telephone: (802) 658-6600 Fax: (802) 860-3732 www.marketforge.com
Superseding All Previous Parts Lists.
MARKET FORGE
P/N 14-0358 Rev B
TABLE OF CONTENTS
MAINTENANCE ........................................................................3
TROUBLESHOOTING ..................................................................4
REPAIR AND REPLACEMENT ..........................................................5
ILLUSTRATED PARTS LIST
KETTLE ...............................................................................6
TILT CONSOLE ...................................................................... 10
CONTROL BOX ...................................................................... 12
HINGE ASSEMBLY ................................................................... 13
SPRING ASSIST HINGE ASSEMBLY .................................................. 14
SPRING ASSIST COVER ASSEMBLY
FOR FIELD INSTALLATION ON FT-LE MODELS ....................................... 15
DRAW-OFF VALVE ................................................................... 16
WIRING DIAGRAMS
F-20LE / F-20PE ..................................................................... 18
F-30LE / F-30PE ..................................................................... 23
F-40LE, F-60LE, F-80LE & F-100LE /
F-40PE, F-60PE, F-80PE & F-100PE .................................................. 28
FT-20LE ............................................................................. 33
FT-30LE ............................................................................. 38
FT-40LE, FT-60LE, FT-80LE & FT-100LE ............................................... 43
FT-40LE, FT-60LE, FT-80LE & FT-100LE
OPTIONAL 33 KW ................................................................... 48
APRIL 6, 2016 2 F-PE, F-LE & FT-LE SERIES ELECTRIC KETTLES
MAINTENANCE
LOW WATER LEVEL
Proper water level must be maintained within the jacket
for the kettle to operate. Depletion of water may occur
from excessive opening of, or leakage through the safety
relief valve.
If water is below required operating level, either initially
at start-up or during use, the kettle will automatically shut
off, refuse to operate and the LOW WATER signal light
will come on.
In order for the kettle to operate, the following procedure
must be followed:
1. Trip the safety relief valve lever to relieve all pressure
from the kettle jacket.
2. At exterior rear of kettle jacket remove nut from Air
Vent.
3. Insert funnel into Air Vent opening and slowly add the
indicated amount of clean water for:
MODELS ADD
20 & 25 gallon
30 gallon
40 gallon
60 gallon
80 gallon
100 gallon
140 ounces
(4.14 litres)
150 ounces
(4.44 litres)
220 ounces
(6.50 litres)
250 ounces
(7.39 litres)
330 ounces
(10.05 litres)
420 ounces
(12.42 litres)
IF COMPLETELY
EMPTY, ADD:
376 ounces
(11.12 litres)
504 ounces
(14.90 litres)
548 ounces
(16.20 litres)
586 ounces
(17.33 litres)
850 ounces
(25.12 litres)
1088 ounces
(32.17 litres)
4. Replace Air Vent nut.
5. Follow Air Venting Instructions below.
6. Continue normal Operating Procedure of kettle.
AIR VENTING INSTRUCTIONS
Periodically check Pressure Gauge when the kettle is
cold. Reading should be in (green) VACUUM zone between 20 to 25, otherwise air is present and efcient heating will not occur.
To remove air, set Thermostat Knob at 8 and heat empty
kettle until TEMPERATURE pilot light goes off.
Open Air Vent nut one full turn for 10 seconds to exhaust
air from kettle jacket. Close Air Vent nut.
SAFETY VALVE MAINTENANCE AND TESTING
CAUTION
Under normal operating conditions a “try lever
test” should be performed every two months.
Under severe service conditions, or if corrosion and/or deposits are noticed within the
valve body, testing must be performed more
often. A “try lever test” should also be performed at the end of any non-service period.
CAUTION
Hot, high pressure uid may be discharged
from body drain and vent during “try lever”
test. Care must be taken to avoid any bodily
contact.
CAUTION
High sound levels may be experienced during
“try lever” test. Wear proper safety equipment
and exercise extreme care! Test at, or near,
half of the operating pressure by holding the
test lever fully open for at least two seconds
to ush the valve seat free of sediment and
debris. Then release lever and permit the
valve to snap shut.
If lift lever does not activate, or there is no
evidence of discharge, turn off equipment immediately and contact a licensed contractor or
qualied service personnel.
APRIL 6, 2016 3 F-PE, F-LE & FT-LE SERIES ELECTRIC KETTLES
TROUBLESHOOTING
The table below gives information to assist service personnel in locating the general source of the problems, which occur
with the self-contained kettles. Before attempting to locate the source of difculty described, the technician should be familiar with basic functioning described in basic functioning under the introduction section.
PROBLEM (PROBABLE CAUSE) REMEDY
1. Indicator light fails to light with switch in ON position and thermostat dial set.
a. Power to kettle is OFF.
b. Kettle tilted (FT__LE Only).
c. Low water level in steam jacket, low water light on.
d. Indicator light burned out.
e. Faulty power switch.
f. Faulty thermostat.
g. Faulty tilt interlock switch of time delay (FT__LE Only).
h. Faulty level control.
i. Faulty wiring.
2. Kettle not hot enough to boil water with thermostat dial set at “10”.
a. Air in kettle jacket.
b. Faulty relief valve.
c. Burned out heating element.
a. Locate external circuit breaker shut-off for incoming
power and place in ON position.
b. Return to full vertical position.
c. Fill jacket.
d. Replace light.
e. Replace switch.
f. Replace thermostat.
g. Replace as required.
h. Replace control.
i. Inspect condition of wire and tightness of all connec-
tors. Correct as required.
a. Open bleed vent one full turn for 10 seconds and
close.
b. Replace valve.
c. Refer to #4. Heating Element Replacement.
3. Low water light on.
a. Low water level in jacket.
b. Defective level control.
4. Kettle hard to tilt (FT__LE models only).
a. Gears dry.
b. Worn trunnion bearings.
a. Fill jacket (refer to operating instructions).
b. Replace control.
a. Apply high quality bearing grease inside console.
b. Disassemble left and right side bearings and replace
as required.
APRIL 6, 2016 4 F-PE, F-LE & FT-LE SERIES ELECTRIC KETTLES
REPAIR AND REPLACEMENT
#1 GENERAL
In the parts section of this manual contains a listing of
alI replaceable parts and associated illustrations of the
kettle. Disassembly procedures will be obvious from the
illustrations, When replacing probes or gauges in the
steam jacket, it is essential to install replacements so as
to obtain a pressure tight seal. Tape sealant should be
used.
#2 MODEL SERIES FT__LE DISASSEMBLY
All controls are accessed by lowering the kettle to the full
tilt position and removing screw and bottom cover. The
tilting gear mechanism is contained inside the console.
Removal of screw and console cover permits access to
gears for service and periodic application of gear grease.
#3 MODEL SERIES F-__PE DISASSEMBLY
To access controls, screw is removed and bottom cover
F-__PE
1. Lay kettle on cover hinge.
2. Remove screws from both
halves of bottom cover.
3. Remove each cover half
separately,
4. Remove nuts from element
5. Remove element.
6. Install new element.
7. Reverse steps 1-4.
F-__LE
1. Lay kettle on cover hinge.
2. Remove anged foot from each leg.
3. Remove screws from bottom cover.
4. Remove cover.
5. Remove, nuts from element.
6. Remove element.
7. Install new element.
8. Reverse steps 1-5.
is slid down to the oor, Repair and testing of contactors
and water level contactors assisted by loosening the separate mounting plate for these components. For all other
controls, it is necessary to reach up inside the kettle.
NOTE: For more extensive repair, it is possible to disas-
semble the pedestal mounting and lift the kettle
off the base plate. After repairs are completed,
the base plate cover must be resealed to the oor
and the pedestal using Silicone sealant.
#4 HEATING ELEMENT REPLACEMENT
Heating elements are replaceable. The kettle is equipped
with three separate protective features – a low water level
control, a tilt shut-off switch and a thermostat control.
Defective elements are isolated by testing each element
with an ohmmeter. If a zero ohm reading cannot be obtained for any element, it is defective.
To replace defective element, proceed as follows:
FT__LE
1. Lay kettle on cover hinge (if so
equipped) or on rear of kettle.
2. Remove screws from bottom
cover.
3. Remove cover.
4. Remove nuts from element.
5. Remove element.
6. Install new element.
7. Reverse steps 1-4.
MODELS KW PHASE
20 gallon kettles 12
30 gallon kettles 15
40 gallon kettles 24 3 67 58 29 63 58
60 gallon kettles 24 3 67 58 29 63 58
80 gallon kettles 24 3 67 58 29 63 58
F-100PE 24
FT-100LE
Optional
F-100LE 24 3 67 58 29 63 58
24 3 67 58 29 63 58
33 3 91.6 79.4 39.7 50.1 45.9
1 57 50 25 - -
3 34 29 15 32 29
1 73 63 32 - -
3 42 37 18 40 37
1 115 100 50 - -
3 67 58 29 63 58
280VAC
AMP
240VAC
AMP
480VAC
AMP
220/380VAC
AMP
240/415VAC
AMP
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KETTLE
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KETTLE
ITEM PART NO. DESCRIPTION
20 30 40 60/80 100
1 97-6392 Hex Bolt, 5/16 - 18 x 3/4" 4 4 4 4 4
**2 97-5019 Element Assembly, 208V, 12 kW 1
97-5020 Element Assembly, 220/380V, 12 kW 1
97-5021 Element Assembly, 240/416V, 12 kW 1
97-5022 Element Assembly, 480V, 12 kW 1
-- Element Assembly, 600V, 12 kW 1
97-5033 Element Assembly, 208V, 15 kW 1
97-5034 Element Assembly, 220/380V, 15 kW 1
97-5035 Element Assembly, 240/416V, 15 kW 1
97-5036 Element Assembly, 480V, 15 kW 1
-- Element Assembly, 600V, 15 kW 1
97-5037 Element Assembly, 208V, 18 kW 1 1
97-5038 Element Assembly, 220/380V, 18 kW 1 1
97-5039 Element Assembly, 240/416V, 18 kW 1 1
97-5040 Element Assembly, 480V, 18 kW 1 1
-- Element Assembly, 600V, 18 kW 1 1
97-5127 Element Assembly, 208V, 24 kW 1 1
-- Element Assembly, 220/380V, 24 kW 1 1 1
97-5128 Element Assembly, 240/416V, 24 kW 1 1 1
97-5130 Element Assembly, 480V, 24 kW 1 1 1
-- Element Assembly, 600V, 24 kW 1 1 1
97-5893 Element Assembly, 208V, 33 kW 1 1 1
-- Element Assembly, 220/380V, 33 kW 1 1 1
-- Element Assembly, 240/416V, 33 kW 1 1 1
97-5876 Element Assembly, 480V, 33 kW 1 1 1
-- Element Assembly, 600V, 33 kW 1 1 1
** SELECT AS REQUIRED
QUANTITY
ITEM PART NO. DESCRIPTION QTY
3 97-5025 Element Gasket
4 97-6513 Power Switch
5 -- Pilot Light - Low Water
6 -- Pilot Light - Temperature 1
7 97-5339 Dial 1
8 97-5012 Bezel 1
9 -- Thermostat 1
10 97-5620 “O” Ring 1
11 97-5002 Pressure Gauge 1
APRIL 6, 2016 7 F-PE, F-LE & FT-LE SERIES ELECTRIC KETTLES
KETTLE
ITEM PART NO. DESCRIPTION QTY
12 97-5147 Pressure Gauge Mounting Plate 1
13 -- Hex Bolt, 5/16 - 18 x 1/2" 1
**14 97-5051 Bottom Cover, (3041-7), FT-20LE 1
-- Bottom Cover, (3041-8), FT-30LE 1
-- Bottom Cover, (3041-9), FT-40LE 1
-- Bottom Cover, (3041-10), FT-60LE 1
-- Bottom Cover, (3041-11), FT-80LE 1
-- Bottom Cover, (3041-12), FT-100LE 1
-- Bottom Cover, (3041-1), F-20LE 1
-- Bottom Cover, (3041-2), F-30LE 1
-- Bottom Cover, (3041-3), F-40LE 1
-- Bottom Cover, (3041-4), F-60LE 1
97-5088 Bottom Cover, (3041-5), F-80LE 1
-- Bottom Cover, (3041-6), F-100LE 1
97-5080 Bottom Cover, F-20PE 1
-- Bottom Cover, F-30PE 1
-- Bottom Cover, F-40PE 1
97-5714 Bottom Cover, F-60PE 1
-- Bottom Cover, F-80PE 1
-- Bottom Cover, F-100PE 1
15 97-5046 Connector, 1/4 cc x 1/4 FPT 1
16 97-5619 Connector, Thermostat 1
17 97-5000 Connector, 1/4 cc x 3/8 MPT 1
18 -- Copper Tube 1/4 x 26", 20 Gallon 1
97-6382 Copper Tube, 1/4 x 28", 30, 40 Gallon 1
-- Copper Tube, 1/4 x 29", 60 Gallon 1
-- Copper Tube, 1/4 x 33", 80 Gallon 1
-- Copper Tube, 1/4 x 35", 100 Gallon 1
**19 97-5609 Contactor, 208, 220, 240V - 12, 15, 18 kW 2
97-5609 Contactor, 380, 220/380, 416, 240/416, 480, 600V, -12, 15, 18 kW 1
97-5610 Contactor, 208, 220, 240V- 24 kW 2
97-5610 Contactor, 480, 600V, 24 kW 1
97-5611 Contactor, 208, 220, 240V - 33 kW 2
97-5611 Contactor, 480, 600V -33 kW 1
20 97-6527 Level Control 1
**21 98-6187 Fuse Block, 600V (380V - 600V) 2
98-6188 Fuse, 1/2 Amp., 600V (380V-600V) 2
97-5476 Fuse, 250V, 3A (208-240V) 2
APRIL 6, 2016 8 F-PE, F-LE & FT-LE SERIES ELECTRIC KETTLES
KETTLE
ITEM PART NO. DESCRIPTION QTY
97-5864 Fuse Holder, (208-240V) 2
97-5476 Fuse, 250V, 3A, (220/380V and 240/415V) 1
97-5864 Fuse Holder (220/380V and 240/415V) 1
**22 97-5616 Transformer, 380-220, 50/60 Hz, 100VA 1
97-5616 Transformer, 415-220, 50/60 Hz, 100VA 1
97-5613 Transformer, 480-240, 60 Hz, 100VA 1
98-6191 Transformer, 600-240, 60 Hz, 100VA 1
23 97-6376 Transformer Fuse Block Mounting Bracket 1
24 98-6186 End Section 1
25 98-6185 Terminal Block Section 3
* 97-6586 Rail 1
**26 -- Component Mounting Plate (2781-1), 20 Gallon 1
-- Component Mounting Plate (2783-1), 30 Gallon 1
-- Component Mounting Plate (2782-1), 40 Gallon 1
-- Component Mounting Plate (2784-1), 60 Gallon 1
-- Component Mounting Plate (2785-1), 80, 100 Gallon 1
27 97-5425 Probe 1
28 97-6368 Down Tube 1
29 97-5009 Relief Valve 1
30 97-5415 Air Vent Assembly 1
**31 97-5658 Control Box Cover (6880-1), 20 Gallon 1
-- Control Box Cover (6880-2), 30 Gallon 1
-- Control Box Cover (6880-3), 40 Gallon 1
-- Control Box Cover (6880-4), 60 Gallon 1
-- Control Box Cover (6880-5), 80 Gallon 1
-- Control Box Cover (6880-6), 100 Gallon 1
*32 97-5647 Control Panel Decal, 30 Gal. 1
-- Control Panel Decal, 40 Gal.
-- Control Panel Decal, 60 Gal.
-- Control Panel Decal, 80 Gal.
-- Control Panel Decal, 100 Gal.
97-5646 Decal (20 Gallon) 1
* NOT SHOWN.
** SELECT AS REQUIRED.
APRIL 6, 2016 9 F-PE, F-LE & FT-LE SERIES ELECTRIC KETTLES
TILT CONSOLE
APRIL 6, 2016 10 F-PE, F-LE & FT-LE SERIES ELECTRIC KETTLES
TILT CONSOLE
ITEM PART NO. DESCRIPTION QTY
1 97-5090 Hand Wheel 1
2 97-5091 Set Screw 3/8 -16 x 1/2" 1
3 -- Tilt Shaft 1
4 97-5822 Segment Gear & Worm Gear Kit (Includes 5 to 11)
5 97-5416 Set Screw, 1/4 - 20 x 1/2 1
6 97-5093 Tension Pin, 3/16 Diameter x 1-1/4" L 1
7 -- Nut 1/2 - 13 1
8 -- Lock Washer, 1/2" 1
9 -- Bolt 1/2 - 13 x 2" 1
10 97-5652 Key Woodruff 1
11 97-5546 Retaining Ring 1
12 97-5096 Jam Nut 2
13 97-5909 Thrust Bearing 2
14 97-5584 Nut, 3/8 - 16 1
15 97-5365 Set Screw, 3/8 - 16 x 1 3/4" 1
16 97-5670
17 97-5368 Stainless Steel Washer 1
18 97-5883 Bolt 1
19 97-5669 Out bore Bearing 1
20 -- Ground ID Tag 1
21 97-5052 Ground Lug 1
22 -- Bolt 3/8-16 x 1" 4
23 -- Lock Washer 3/8" 4
24 97-5547 Block Bearing 1
25. -- Micro Switch Bracket 1
26 97-5414 Micro Switch 1
27 -- Micro Switch Activator Bracket 1
28 -- Terminal Block Bracket 1
29 -- Spacer, 1/16" Thick As Required
30 98-6185 Terminal Block 3
31 98-6186 End Section 1
* 97-6586 Rail 1
* 32. -- Screw, Console Cover, 10 - 32 x 1/2" 1
33 -- Decal - Tilt 1
34 97-5820 Washer, 3/4 ID x 1-1/4" OD 1
35 97-5821 Cotter Pin S.S. 3/16" x 1" L. 1
* NOT SHOWN
Out bore Bearing complete with extension - used on spring assist covers only specify model.
1
APRIL 6, 2016 11 F-PE, F-LE & FT-LE SERIES ELECTRIC KETTLES
CONTROL BOX
ITEM PART NO. DESCRIPTION QTY
1 97-5032 Adjustable Flanged Foot 3
2 -- Console Box 1
3 -- Console Cover 1
4 -- Screw 10 - 32 x 1/2" 1
APRIL 6, 2016 12 F-PE, F-LE & FT-LE SERIES ELECTRIC KETTLES
HINGE ASSEMBLY
ITEM PART NO. DESCRIPTION QTY
1 97-5008 Knob 1
** 2 97-5596 Handle Assembly, 20 Gallon Kettle 1
97-5597 Handle Assembly, 30 Gallon Kettle 1
97-5598 Handle Assembly, 40 Gallon Kettle 1
3 97-5200 Bolt 2
4 97-5579 Fiber Washer 4
5 97-5601 Nut 2
6 97-5471 Cover, 20 Gallon Kettle 1
97-5723 Cover, 30 Gallon Kettle 1
97-5053 Cover, 40 Gallon Kettle 1
97-5054 Cover, 60 Gallon Kettle 1
97-5594 Cover, 80 Gallon Kettle 1
97-5595 Cover, 100 Gallon Kettle 1
* * SELECT AS REQUIRED
APRIL 6, 2016 13 F-PE, F-LE & FT-LE SERIES ELECTRIC KETTLES
SPRING ASSIST HINGE ASSEMBLY
APRIL 6, 2016 14 F-PE, F-LE & FT-LE SERIES ELECTRIC KETTLES
SPRING ASSIST HINGE ASSEMBLY
ITEM PART NO. DESCRIPTION QTY
97-5464 HINGE ASSEMBLY
1. 97-5352 Lock Pin 1
2. 97-5343 End Lock Plate 1
3. 98-5354 Stationary Disc 1
4. 98-6074 Core 1
5. 97-5160 Spring 1
** 6. 97-5585 Handle Assembly, 20 Gallon Kettle 1
97-5586 Handle Assembly, 30 Gallon Kettle 1
97-6388 Handle Assembly, 40 Gallon Kettle 1
97-5059 Handle Assembly, 60 Gallon Kettle 1
97-5587 Handle Assembly, 80 Gallon Kettle 1
97-5588 Handle Assembly, 100 Gallon Kettle 1
7. 97-6391 Rotary Disc 1
8. 97-5356 End Stop Plate 1
9. 97-6392 Cap Screws 4
10. 97-5008 Knob 1
11. 97-6393 Mounting Plate Assembly - Tilting Models Only 1
** 12. 97-5471 Covers, 20 Gallon Kettle 1
97-5723 Covers, 30 Gallon Kettle 1
97-5053 Covers, 40 Gallon Kettle 1
97-5054 Covers, 60 Gallon Kettle 1
97-5594 Covers, 80 Gallon Kettle 1
97-5595 Covers, 100 Gallon Kettle 1
** SELECT AS REQUIRED.
SPRING ASSIST COVER ASSEMBLY
FOR FIELD INSTALLATION ON FT-LE MODELS
PART NO. DESCRIPTION
4225-1 FT-20LE
4225-2 FT-30LE
97-6733 FT-40LE
97-5581 FT-60LE
4225-5 FT-80LE
4225-6 FT-100LE
ITEMS NOT SHOWN
APRIL 6, 2016 15 F-PE, F-LE & FT-LE SERIES ELECTRIC KETTLES
DRAW-OFF VALVE
APRIL 6, 2016 16 F-PE, F-LE & FT-LE SERIES ELECTRIC KETTLES
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