Market Forge FT-100GL Service Manual
FT-GL & FT-GLF SERIES
2/3 AND FULLY JACKETED GAS TILTING KETTLES
PARTS AND SERVICE MANUAL
EFFECTIVE SEPTEMBER 16, 2014
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.
44 Lakeside Avenue, Burlington, Vermont 05401 USA Telephone: (802) 658-6600 Fax: (802) 860-3732
Superseding All Previous Parts Lists.
MARKET FORGE INDUSTRIES
www.mi.com
P/N 14-0360 Rev A (9/14)
TABLE OF CONTENTS
ADJUSTMENTS .......................................................................3
TROUBLESHOOTING ..................................................................6
ILLUSTRATED PART LIST
KETTLE ...............................................................................8
FT-20GL TILTING MECHANISM ....................................................... 10
TILT CONSOLE AND PARTS .......................................................... 12
INTERIOR COMPONENTS ........................................................... 15
SPRING ASSIST HINGE ASSEMBLY .................................................. 18
DRAW OFF VALVE ................................................................... 19
WIRING - 120V, 1 PHASE ............................................................ 21
WIRING - 220-240V, 1 PHASE ........................................................ 23
SEPTEMBER 16, 2014 2 FT-GL & FT-GLF SERIES GAS KETTLES
ADJUSTMENTS
GENERAL
When any difculty arises always check that the unit has
been connected to the gas supply type and voltage for
which it was supplied. This can be done by examining
the serial plate on the lower right side of the unit. It will
list the gas type and voltage for which the unit was manu-
factured.
Wiring diagrams for the unit are located in a small enve-
lope afxed to the side panel of left hand console.
UNIT
FT-20GL
FT-30GL
FT-40GL
FT-60GL
TOTAL INPUT
BTU/HOUR
80,000
100,000
100,000
120,000
ORIFICE SIZE
Natural Propane
DMS # 19
(.166")
DMS # 13
(.185")
DMS # 13
(.185")
DMS # 7
(.201")
DMS # 30
(.125")
DMS # 27
(.144")
DMS # 27
(.144")
DMS # 23
(.154")
MANIFOLD PRESSURE
Natural Gas 3.5 inches W.C
LP Gas 4 inches W.C.
THERMOSTAT
The thermostat adjustment should not be changed.
Check the following before changing the thermostat.
1. With kettle cold, the pressure on the pressure gauge
should read in the green vacuum zone (25 to 30 inches Hg vacuum). If not, see ‘Re-establishing Vacuum”
section.
2. The pressure switch may be set too high or too low
and causing the out of adjustment condition. A voltmeter should be used by a properly trained service-
man to determine if the pressure switch or thermostat
is actually cycling the burners. If the pressure switch
is found to be cycling the burners, see “Pressure
Switch” section.
After verifying that the pressure switch is set and operat-
ing properly, the thermostat may be adjusted using the
set screw inside the stem. At maximum setting, the thermostat should cycle off at a gauge pressure reading of 30
psi. Turn set screw clockwise to decrease pressure and
counterclockwise to increase pressure.
ADJUSTMENTS
WARNING
Adjustments and service work may be per-
formed only by a qualied technician who is
experienced in, and knowledgeable with, the
operation of commercial gas cooking equip-
ment. To assure your condence, contact your
authorized service agency for reliable service,
dependable advice or other assistance, and
for genuine factory parts.
SEPTEMBER 16, 2014 3 FT-GL & FT-GLF SERIES GAS KETTLES
ADJUSTMENTS
PRESSURE SWITCH
The pressure switch should not be adjusted until it is determined to be the cause of an operating pressure dif-
culty. See “Thermostat” section to determine if the source
of difculty is the pressure switch or thermostat.
The major difculties caused by pressure switch mis-ad-
justment are:
1. Pressure relief valve opening, pressure rises above
45 psi.
2. Pressure in kettle is less than 30 psi and burner is
being shut down by pressure switch (not thermostat).
The pressure switch is preset for proper operation from
the factory. It is adjusted to the maximum pressure which
will prevent the pressure relief valve from opening. Dur-
ing preheat to the maximum thermostat setting (275EF),
from either a cold condition or a lower temperature setting, the temperature may overshoot the thermostat set-
ting and be shut down by the pressure switch. This is
normal, however, after the kettle has cycled several times
(empty) the thermostat will begin cycling the unit.
TO ADJUST PRESSURE SWITCH:
1. To obtain access to the pressure switch, the front
panel must be removed. Remove the screws on bot-
tom of the panel. Be sure to support the panel to
avoid excessive strain on the wiring.
2. To increase the pressure switch setting, turn the white
ribbed knob clockwise; to decrease, turn it counterclockwise. Use the centre of the black ring as an in-
dicator.
3. With the kettle empty and completely cold, turn kettle
on and set thermostat to maximum setting (275EF).
4. The pressure in kettle (read pressure gauge on front
panel) should reach a maximum of 30 psi and pressure relief valve should not open. Kettle pressure
may rise 3 or 4 psi even after burners shut down.
5. Relief valve should not open when kettle pressure is
45 psi; pressure switch setting is satisfactory.
6. If the safety relief valve opens, reduce setting on
pressure switch, cool kettle completely by running
cold water through it and repeat steps 3 - 6.
7. If pressure in kettle is below 30 psi increase setting
of pressure switch, cool kettle completely by running
cold water through it and repeat steps 3 - 7.
ADDING WATER (Low water light comes on)
It may be necessary to replenish water in the jacket when
the low water indicator comes on. Do so as follows:
1. Unit should be completely cold and off.
2. Lift handle of pressure relief valve to release vacuum
in kettle. (Relief valve is at left rear of kettle.
3. Remove air vent nut on the elbow located at the rear
left of the unit.
4. Using pure distilled water only, pour the water into
the opening (a funnel will be helpful). Water will enter the kettle slowly, as air must escape through the
same hole. Water should be added until water level
at the sight glass is half way between the minimum
and maximum levels.
5. When sufcient water has been added, replace and
tighten the nut. Be sure to seal threads with a pipe
joint compound suitable for steam at 50 psi.
6. Vacuum must be re-established (See Re-establishing
Vacuum).
FOR REFERENCE:
The total amount of distilled water to be added when low
level pilot is illuminated:
FT-20GL 169 . oz. (5 L)
FT-30GL & FT-40GL 270 . oz. (8 L)
FT-60GL 372 . oz. (11 L)
RE-ESTABLISHING VACUUM
Periodically check pressure gauge when kettle is cold.
Reading should be in green vacuum zone (below 0 psi).
Otherwise air is present and proper heating will not occur. Use the following procedure to remove air and re-
establish vacuum:
With the kettle empty, turn the thermostat knob to the
highest temperature. When the temperature pilot light
goes off, open air vent nut one (1) full turn for 20 seconds
and then close and tighten the nut. This should remove
the air and any loss in performance should return.
Should the kettle fail to maintain a vacuum after repeated
attempts to establish vacuum, further checks should be
made to see if the pressure relief valve is leaking or if
there are any leaks in the pressure relief valve piping,
copper lines going to the pressure switch, pressure gauge
or thermostat tting.
8. Allow the kettle to cycle several times to verify the
correct pressure setting.
9. Replace the front panel when adjustment is complete.
SEPTEMBER 16, 2014 4 FT-GL & FT-GLF SERIES GAS KETTLES
ADJUSTMENTS
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 corro-
sion 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 im-
mediately and contact a licensed contractor or
qualied service personnel.
SEPTEMBER 16, 2014 5 FT-GL & FT-GLF SERIES GAS KETTLES
TROUBLESHOOTING
PROBLEM LOOK FOR
Motor will not run.
Motor runs, no spark.
Motor runs, spark present, no gas ignition.
• No current. Check that power is being supplied to the unit.
• Defective thermostat or pressure switch.
• Defective motor.
• Motor overload out.
• Blown fuse.
• Defective transformer.
• Defective ignition module.
• Blown fuse on ignition module.
• Defective spark electrode (cracked insulator).
• Defective ignition cable.
• Defective centrifugal switch on motor.
• Manual main valve off.
• Mislocated spark or ground rods.
• Defective valve.
• Defective ignition module.
Low water light comes on.
Relief valve opens.
Flame burns only about 6 seconds and shuts off.
• Burner rate set too high. Ensure that manifold pressure is set per
rating plate and that correct orice size installed
• Burner getting too much air. Reduce air shutter opening (not below
1.0).
• Add water - See previous section ADJUSTMENTS.
• Pressure switch set too high.
• Pressure gauge is not accurate.
• Relief valve is faulty
• Flame rod or ame ground mislocated.
• Defective ame rod wire.
• Defective ignition module.
• Burner rate set too high. Ensure that manifold pressure is set per
rating plate and that correct orice size installed
• Burner getting too much air. Reduce air shutter opening (not below
1.0).
SEPTEMBER 16, 2014 6 FT-GL & FT-GLF SERIES GAS KETTLES
TROUBLESHOOTING
PROBLEM LOOK FOR
Short ame.
Long hazy ame.
Gas fails to shut off.
NOTE: Loose, broken or grounded wiring may cause many of the symptoms listed. Check all wiring and make sure it is intact.
• Wrong size orice.
• Low gas pressure.
• Air shutter adjustment.
• Main manual valve partially closed.
• Wrong size orice.
• High gas pressure.
• Dirty blower wheel or intake.
• Air shutter adjustments.
• Dirt on valve seat.
• Defective main valve.
SEPTEMBER 16, 2014 7 FT-GL & FT-GLF SERIES GAS KETTLES
KETTLE
SEPTEMBER 16, 2014 8 FT-GL & FT-GLF SERIES GAS KETTLES
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