Market Forge M24E18 Installation Manual

ELECTRICALLY OPERATED

FACSIMILE tt

(617) 387

-

4456

35 Garvey St., Everett, MA

02149

-

4403

Tel.

(617) 387

-

STEAM GENERATOR

OWNERS MANUAL

OUTSIDE MA [phone]

Form No. S-2379 Printed in U.S.A. 3/90

MODELS:

M24E18, M24E24, M24E32,
M24E36, M24E42, M24E48,
M36E18, M36E24, M36E32,
M36E36, M36E42, M36E48

4100, Telex 94-9414, Cable MAFORCO

TABLE OF CONTENTS

Page

Introduction................................................................. 1

How To Use This Manual ..................................... 1

Theory of Operation ................................. 1

Receiving Instructions..................................... 2

Installation Instructions........................ 2,3

Operating Instructions................................................... 4,5

Liquid Level Control Diagram..................................... 6, 8

Trouble Shooting Liquid Level Control Board ..................... 7, 9

General Trouble Shooting Guide ......................................... ....................10,11,12

Operation/Adjustment of Pressure Reducing Valves ............. 13

Adjustment, Pressure Control Switches ........................ 14

Control Box Wiring Diagram ..................................... 15

Wiring Diagram, Heating Circuit ............................... 16

Wiring Diagram, Heating Circuit (Export) ..................... 17

24" Cabinet Base .................................... 18

36" Cabinet Base ................................................ 19

Steam Generator - Right Side View............................. 20

Control Box Assy. (Covered & Uncovered) .......................... 21

Heating Elements......................................................... 22

Plumbing Section (Left Side View)................................ 23

Contactors & Liquid Level Control Box ................................ 24

A - Small Generator w/Contactor Box ................................... 25

B - Large Generator w/Contactor Box.................................. 25

C - Electric Modular Base Steam Generator.......................... 25

INTRODUCTION

Market Forge, in the interest of both costs and efficiency to the purchasers of its equipment, has designed these steam
generators with the latest type automatic controls in order to make it easier for the operator to use and maintain this
equipment. In addition, standard components are utilized on all models of steam generator equipment unless variances in
size or capacity dictate a divergence from this policy for more efficiency in operation. This parts and service manual is written
and illustrated to cover all steam generator equipment that uses electricity as a source of power other than those which have
been custom designed under special order.

HOW TO USE THIS MANUAL

The pictures of components are aids to the identification, disassemb ly and assembly of parts. The parts listings provide
information necessary for the ordering of replacement parts (proper part names and part numbers). When requesting parts or
service, always furnish the model and serial number of your complete unit, which will indicate to Market Forge Service
Division the type of steam generator with which you are equipped. This information can be found on the nameplate attached
to the steam generator frame.

THEORY OF OPERATION FOR ELECTRIC STEAM GENERATORS

Explanation of how the control system works on manual and automatic electric steam generators.
With the steam generator filled with water to its proper level and the fuel switch turned to its on position, the contactors will

pull in and permit the completion of the electric circuit to the heating elements. When the steam generator builds up to its set
pressure the pressure switch on the left side in the control box opens. This will open up the circuit to the coil in the contactor,
which in turn will drop out the contacts in the contactor and shut off the electricity. As the pressure in the steam generator
drops off, the pressure control switch will again come into operation and complete the circuit and build the steam generator
back up to its set pressure. When the operator wishes to stop all generation of steam he need only to place the fuel switch in
the off position.

Product Service Dept. Market Forge Co.

35 Garvey Street Telephone [phone]

35 Garvey St., Everett, MA 02149 Tel. [phone]

ELECTRICALLY OPERATED STEAM GENERATORS

WARNING: READ THIS BEFORE OPENING THE SHIPPING CONTAINERS
DO NOT AT ANY TIME LAY THE EQUIPMENT DOWN ON ITS BACK, SIDE, TOP OR FRONT. Doing so may damage

the equipment and invalidate the warranty.

RECEIVING INSTRUCTIONS:
Inspect the equipment before signing the bill of lading. The equipment supplied was tested and inspected before

shipment. The carrier accepted it as complete and without damage.
This merchandise became your property when it was accepted by the carrier at the factory. Market Forge cannot assume

responsibility for loss or damage during transit.
For this reason, you should immediately inspect for visible and concealed dama ge or shortages before signing for

shipment as follows:

1. Count the number of cartons and packages received to be sure they coincide with the bill of lading.

2. Visually check all cartons for external damage.

3. Remove all cartons from their skids to examine equipment for concealed damage. The carton is
nailed and strapped to the skid. It will be necessary to cut the straps and pry off the container.

4. After inspection, replace the cartons over the equipment on the skids to protect and secure the
equipment until it is ready for installation.

5. Sign for shipment if all is in order. Note shortages, external and concealed damage, if any, on the
bill of lading before accepting a partial or damaged shipment.

6. If necessary, contact the carrier immediately to file a claim. All claims must be filed by the receiver.

7. Do not remove the cartons or the skids from the cooking equipment until the unit has been
transported through the building to the actual set -up location. The cartons should remain on the
equipment as protection against dents and scratches.

Installation Instructions

SETTING IN PLACE:

INSTALLING LEGS:
Some models are shipped without legs. A separate carton will contain the legs. If your model is received this way be sure

to follow the installation sheet packed with the legs.

LEVELING:

In order for the steam generator to drain correctly it is important that it be level. Place level on cabinet top - both left and
right and front to back. If not level, adjust feet. On compartment cookers, check cooking compartment pan supports to
insure they are secure. Check by installing cooking pan to see if the pan supports are level.

PANELS AND DOORS:

Panels and doors for the cabinet may be shipped separate. Refer to installation instructions enclosed with panels and
doors for method of attaching. It is recommended that panels and doors be installed after mechanical connections are
made to avoid damage.

2

Volts 18KW 24KW 32KW 36KW 42KW

1ph 3ph 3ph 3ph

3ph 3ph 3ph

240(220

-

240) 75 32 60 77 91

—

116

480 (360

-

500) 36 22 32 39 47

—

58

HW

2

amps.

adjacent steam powered equipment.

INSTALLATION ROUGH-IN REQUIREMENTS

EP Power Supply —Use wire suitable for at least

90°C. Nominal amp per line wire:

208(197.219) 86 50 66 89 100 117 —

Details of other electrical systems available upon request.

Hot Water— 3/8" N.P.T. for hot water to steam generator.
Hot water line shall have a maximum of 50 PSI (3.5 kg/cm2
and a minimum of 25 PSI (7.8 kg/cm22) water pressure.

CW

Cold Water—3/8" N.P.T. for cold water to condenser. Cold
water line shall have a maximum of 50 PSI (3.5 kg/cm2)
and a minimum of 25 PSI (1.8 kg/cm2) water pressure.

D

Drain—Pipe full 2" (50mm) I.P.S. to flush floor drain
capable of receiving water flowing at a maximum rate of 5
gallons 19 liters per minute. DO NOT MAKE SOLID
CONNECTION TO FLOOR DRAIN. PVC and CPVC are
not acceptable materials for drains.

EC Electrical Connection—120 volts AC, 60Hz,' single phase,

1/2" 13mm conduit connection or equivalent. Use wire
suitable for at least 90°C. Amp draw for generator controls:

ST Steam Take-off—Connecting locations for operation of

CAUTION:
Before connecting water to this unit, water supply

should be analyzed to make sure hardness is no
greater than 2.0 grains and pH level is within the
range of 7.0-8.5. Water which fails to meet these
standards should be treated by installation of a water
conditioner. EQUIPMENT FAILURE CAUSED BY
INADEQUATE WATER QUALITY IS NOT COVERED
UNDER WARRANTY .

3

Operating Instructions

MARKET FORGE MODULAR STEAM GENERATOR OPERATING INSTRUCTIONS

WARNING: The installation of this appliance is to be in accordance with the current CAN 1-B149. 1 of CAN1-

B149.2 - Installation Code for Gas Burning Appliances and Equipment and/or Local Codes.
WARNING: All Electrical connections are to be made in accordance with CSA C22.1 Canadian Electrical Code
Part 1 and/or Local Codes.

Market Forge has two types of steam generators; one has an automatic drain, the other a manual one. To determine which
you have, open cabinet doors and you will see a control box with 2 switches and an indicator light. Instruction label on the
control box will identify the steam generator as being automatic or manual.

DAILY OPERATING, SHUT DOWN & CLEANING INSTRUCTIONS FOR

AUTOMATIC STEAM GENERATORS

First check to be sure that:

A. WATER switch is in the off position.

B. WATER supply valve is OPEN.

C. ELECTRICITY is connected.

D. That STEAM is turned on.

E. Proceed with daily operating procedure.

DAILY OPERATING PROCEDURE

STEP 1 Flip WATER switch from OFF to ON.

STEP 2 Wait 6 minutes for water to fill in steam generator.

(Gauge glass should indicate approx. 2/3 full.)

STEP 3 Flip heat switch from ON to OFF and release back to ON. Indicator

light will come on immediately (This is necessary to manually reset
the unit.) This also turns on HEAT.

DAILY SHUT-DOWN AND CLEANING

STEP 1 Flip WATER switch OFF. (Indicator light will go out and

steam generator will automatically drain.)

STEP 2 After steam generator has completely drained, repeat Steps 1 & 2.

Water is to remain in steam generator until next day use.

STEP 3 Repeat Steps 1 & 2.

Water is to remain in steam generator until next day use

NOTES: If generator is not to be in use for extended periods, (2-3 mos.) contact your authorized

service dealer, for it must be cleaned and drained completely. Then add PM-Plus as per
instructions on Bottle.

If steam generator does not automatically drain when water switch is shut off, open manual
drain by turning knob counter clockwise. Electric steam generators should be blown-down
and refilled after every 4 hours of operation.

DAILY OPERATING, SHUT-DOWN & CLEANING INSTRUCTIONS

First check to be sure that:

A. WATER and HEAT switches are in the OFF position.
B. WATER supply valve is OPEN.

C. ELECTRICITY is connected to ALL units.
D. STEAM is turned on.

E. Proceed with daily operating procedure.

DAILY OPERATING PROCEDURE

STEP 1 Close STEAM GENERATOR DRAIN VALVE.
STEP 2 Flip WATER switch from OFF to ON.
STEP 3 Wait 6 minutes for water to fill in steam generator. (Gauge glass should be 2/3 full.)
STEP 4 Flip WATER switch from ON to OFF and back to ON immediately.

Indicator light will come on. (This is necessary to manually reset the unit.)

STEP 5 Flip HEAT switch from OFF to ON. This turns on HEAT.

DAILY SHUT-DOWN AND CLEANING

STEP 1 Flip HEAT and WATER switches to OFF. (Indicator light will go out.)
STEP 2 Open steam generator drain valve, and drain completely.
STEP 3 Repeat Steps 1 & 2 of DAILY OPERATING PROCEDURE, (Water to

remain in steam generator until next daily use.)

STEP 4 For shutdown for extended periods steam, generator must be cleaned and drained

completely. Refer to steam generator cleaning instructions for modular steam
generators S-2299 for complete instructions.

CAUTION: BE SURE TO READ

Keep this appliance area free and clear from combustibles.
Do not obstruct the flow of ventilation air.
Keep this manual for future reference.
Contact the factory, the factory representative, or a local service company to perform maintenance and repairs.

In the event of a power failure, attempt should not be made to operate the appliance during power failure. Be sure water
switch is in the down position.

TEST PROCEDURES - MARKET FORGE #08-6328 (120V)

MARKET FORGE #08-6329 (240V)

The following is a troubleshooting guide designed to find out if the Dual Function Control is working properly. It
is not designed to find out why the control has failed.

The Series Dual Function control is two controls in one, one half being the feed water control, the other half the
low level cutoff portion.

Tools Needed: A digital or analog V-O-M (volt-Ohm-milliamp meter) and a set of test jumpers (alligator type).

1) Turn off power to the control.

2) Remove the wires #-100, #101, #102 from the probe connections "H, "LLCO" and "G".

3) Remove the wires from the contact connections "COM", #104 and "N.O." from both relays. CAUTION:

Internal Jumper from "L1" to "COM" will be hot when power is reapplied. Temporarily tape free end.

4) Using the Ohm meter, check to see if the normally opened contact is open and the normally closed contact is
closed.

5) Turn power on to control. Check with the voltmeter to see if the voltage being applied to "L1" & "L2" is 120
VAC (+10% -15%), or 240 VAC if so equipped.

6) When power is turned on, the LED on the side away from the transformer should light and the relay next to
the LED should be energized. Checking with the Ohm meter, the normally open contact should be closed and
the normally closed contact should be open. Bringing power to the control should not change the side of the
control that contains the transformer.

7) Place a test jumper wire from either "G" terminal to the "H" terminal. After a 10 second (+/-2) time delay, the
LED will go out and the relay next to this LED should deenergize returning the contacts to their original state,

(Normally open should be open, Normally closed should be closed)

8) Removing the test jumper from "G" and "H" should relight the LED and energize the relay.

9) Place a test jumper wire from either "G" terminal to the "LLCO" terminal. The LED next to the transformer

should light and the relay next to the transformer should energize. Checking with the Ohm meter, the normally
open contact should be closed and the normally closed contact should be open.

10) Remove the test jumper from "G" and "LLCO". The LED should remain lit for about 3 seconds (+/-) before
going out. The relay should deenergize at this time. The contac ts should return to their original state.

11) If the above test shows that the control is operating properly, check all probe and solenoid wiring and the
condition of the electrodes (clean insulator) in the steam chamber. Check the conductivity of the liquid to make

sure it is below 4.7K ohms/cm.

12) If after replacing all wires, the system still does not operate properly, contact the factory.