Market Forge M24E24A Installation Manual

0

OWNER’S MANUAL

WARNING:

IMPROPER INSTALLATION, ADJUSTMENT,

ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE

PROPERTY DAMAGE, INJURY OR DEATH. READ THESE

INSTALLATION, OPERATION AND MAINTENANCE

INSTRUCTIONS THOROUGHLY BEFORE INSTALLING

OR SERVICING THIS EQUIPMENT.

Form Number: S-3112 REV. E 04/14
Printed in USA 35 Garvey Street, Everett, MA 02149

Telephone [phone], Fax [phone]

[e-mail], www.mfii.com

FOR YOUR SAFETY:

DO NOT STORE OR USE GASOLINE OR OTHER

FLAMMABLE VAPORS OR LIQUIDS IN THE

VICINITY OF THIS OR ANY OTHER APPLIANCE.

Electric Operated Boilers

MODELS: □ M24E24A □ M36E24A

□ M24E36A □ M36E36A
□ M24E42/48A □ M36E42/48A

1

Table of Contents

INTRODUCTION ............................................................................................................................... 2

To the Kitchen Manager: ............................................................................................................. 2

INSTALLATION INSTRUCTIONS ........................................................................................................ 3

GAS OPERATED BOILERS ............................................................................................................. 3

RECEIVING INSTRUCTIONS: ......................................................................................................... 3

INSTALLING LEGS: ........................................................................................................................ 3

LEVELING: .................................................................................................................................... 3

SERVICE CONNECTIONS: ............................................................................................................. 4

OPERATING INSTRUCTIONS ............................................................................................................ 5

CONTROL PANEL: ........................................................................................................................ 5

OPERATING THE STEAM GENERATOR: ........................................................................................ 5

ADJUSTMENTS ................................................................................................................................ 6

SETTING THE BOILER CONTROL PRESSURE SWITCHES: .............................................................. 6

PRESSURE CONTROL SWITCH ADJUSTMENT: ............................................................................. 6

GENERAL TROUBLE SHOOTING ....................................................................................................... 7

TESTING PROCEDURE ...................................................................................................................... 9

WATER CONTROL BOARD TESTING PROCEDURE ........................................................................ 9

ILLUSTRATED PARTS LIST .............................................................................................................. 11

BOILER BASE - 24” ..................................................................................................................... 11

PRESSURE SWITCH BOX, WITHOUT COVER .............................................................................. 12

CONTROL BOX ASEMBLY, WITH & WITHOUT COVER ............................................................... 13

ELECTRIC BOILER, LEFT SIDE VIEW – 36”................................................................................... 14

ELECTRIC BOILER, FRONT VIEW – 36” ....................................................................................... 15

ELECTRIC BOILER, CONTACTOR BOX ......................................................................................... 16

ELECTRIC BOILER, ELEMENTS .................................................................................................... 17

ELECTRICAL INFORMATION .......................................................................................................... 18

Wiring Diagram for New Generation Electric Boilers ............................................................... 18

Schematic Diagram for New Generation Electric Boilers ......................................................... 19

Wiring – 18 kW, 24 kW, 32 kW ................................................................................................. 20

Wiring – 18 kW, 24 kW, 32 kW ................................................................................................. 21

Wiring – 36 kW, 42 kW, 48 kW ................................................................................................. 22

Wiring – 36 kW, 48 kW .............................................................................................................. 23

MAINTENANCE .............................................................................................................................. 24

Cleaning the Boiler: ................................................................................................................... 24

CLEANING INSTRUCTIONS: ........................................................................................................ 24

APPLICATION INSTRUCTIONS ........................................................................................................ 26

Application Instructions for Total Concept Descaler Cleaning of the Boiler ............................ 26

2

INTRODUCTION

To the Kitchen Manager:

1. Read this manual carefully and in its entirety. Contact Market Forge Ind., Inc. for

clarification if necessary.

2. Protect your kitchen personnel from scalding and other serious injury by providing

training programs to acquaint all equipment operators with the correct and safe
methods of operation.

3. Operators must be made aware of the consequences of misuse. Steam producing

equipment, no matter who the manufacturer, is inherently dangerous when misused.
The possibility of serious scalding always exists, the careless and/or untrained operator
will be injured.

4. This equipment must be maintained according to the guidelines in this manual (see

"maintenance"). Lack of maintenance will lead to a potentially hazardous condition and
possible liability. Operators should report any equipment malfunction immediately and
steps must be taken to correct the problem before further use of the equipment is
allowed.

5. Keep this manual for daily reference.

Market Forge, in the interest of both cost and efficiency has designed these steam boilers with
the latest automatic controls in order to make it easier for the operator to use and maintain
this equipment. Standard components are utilized on all models unless variances in size or
capacity dictate a divergence from this policy for more efficiency of operation. This parts and
service manual is written and illustrated to cover all steam boiler equipment that uses gas as a
source of fuel 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, disassembly and assembly of parts.
The parts listing provides 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, this will indicate to Market Forge Service Personnel the
type of boiler that you have. This information can be found on the nameplate attached to the
boiler frame.

THEORY OF OPERATION FOR ELECTRIC BOILER:

An explanation of how the control system operates on automatic electric boilers follows:
With the boiler filled with water to the proper level and the fuel switch is turned ON, the
contactors will pull in and permit the completion of the electric circuit to the heating element.
When the boiler builds to its set pressure, the pressure switch opens. This will open the circuit
to the coil in the contactor, which in turn will drop put the contacts in the contactor and shut
off the electricity. As the pressure in the boiler drops the pressure control switch will again
complete the circuit and build the boiler back to its set pressure. To stop all steam generation
place the fuel switch to the OFF position.

3

INSTALLATION INSTRUCTIONS

WARNING:

READ THIS BEFORE OPENING THE

SHIPPING CONTAINER!

ELECTRIC OPERATED BOILERS

MODELS: • M24E24A • M36E24A

• M24E36A • M36E36A

• M24E42/48A • M36E42/48A

CAUTION: BE SURE TO READ:
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 damage 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.

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 instruction sheet packed with the legs.

LEVELING:

In order for the boiler to drain correctly, it is important to use a level on cabinet top both left
and right and front-to-back. If not level, adjust feet. On compartment cookers, check the
interior shelves for level condition.

4

SERVICE CONNECTIONS:

Electric Operated

EP

Power Supply – Use wire suitable for at least
90oC nominal amp per line wire:

24kW

36kW

42kW

48kW

Volts

3 pH

3 pH

3 pH

3 pH

208 (197-219)

66

100

117

--

240 (220-240)

60

91

--

116

480 (360-500)

32

47

--

58

Details of other electrical systems available upon
request

CW1

Cold Water - 3/8” (10mm) O.D. tubing for cold
water to boiler. Cold water lines will have a max
of 50PSI (3.5 kg/cm2) and a min of 25PSI (1.8

kgcm2) water pressure. CAUTION: FILTER
SYSTEM INSTALLATION INSTRUCTIONS MUST BE
ADHERED TO WHEN CONNECTING A FILTER TO
THIS LINE.

CW2

Cold Water - 3/8” (10mm) O.D. tubing for cold
water to condenser. Cold water lines will have a
max of 50PSI (3.5 kg/cm2) and a min of 25PSI (1.8

kg/cm2) water pressure.

D

Drain - Pipe full 2” (51mm) IPS to flush floor
drain capable of receiving water flowing at a max
rate of 5 gallons (19 liters) per minute. DO NOT
MAKE SOLID CONNECTION TO FLOOR DRAIN.

ST

Steam Take-off - Connection for operation of
adjacent steam powered equipment.

NOTE: If equipment is installed where elevation exceeds
2,000 feet (609.6 meters) above sea level, specify
installation altitude so that proper gas orifices can be
provided.

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 water conditioner.
EQUIPMENT FAILURE CAUSED BY INADEQUATE
WATER QUALITY IS NOT COVERED UNDER
WARRANTY.

NOTE: PVC & CPVC PIPE ARE NOT ACCEPTABLE

MATERIALS FOR DRAINS.

WARNING:

DO NOT UNDER ANY CIRCUMSTANCE CONNECT

THE EXHAUST DRAIN LINE DIRECTLY TO A SEWER

LINE.

WASTE LINE INSTALLATION: The drain port of the unit
is marked with a colored tag and is located at the
lower rear left side of the boiler as viewed from the
front. This exhaust line may be left open if the boiler
has to be situated in a tiled floor depression or a tiled
curb section that is equipped with drain facilities. If

this is not the case, then a 2” (51mm) NPT. drain line

must be connected to divert the exhaust to the floor
drain. If it is necessary to use more than three elbows,
increase the size of the waste line accordingly.

NOTE: The only available space to supply utilities to

the gas boiler is the 6” (152mm) space between the
floor and the cabinet. Allow 3” (76mm) space from

side wall and 6” (152mm) from real wall if adjoining
walls are combustible.

INSTALLATION INSTRUCTIONS

5

OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS FOR 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 TO ALL UNITS.
D. THEN PROCEED WITH DAILY OPERATING PROCEDURES.

DAILY OPERATING PROCEDURE:

STEP 1: PRESS WATER SWITCH FROM OFF TO ON.
STEP 2: WAIT 5-10 MINUTES FOR WATER TO FILL IN STEAM GENERATOR (GAUGE GLASS

SHOULD BE 2/3 FULL.)

STEP 3: PRESS HEAT SWITCH FROM ON TO OFF AND RELEASE BACK TO ON WHEN THE

LOW WATER LIGHT GOES OFF. GREEN INDICATOR LIGHT WILL COME ON. (THIS
IS NECESSARY TO MANUALLY RESET THE UNIT.)

DAILY SHUT DOWN AND CLEANING:

STEP 1: STEP 1 PRESS WATER SWITCH OFF. THIS WILL DRAIN THE STEAM GENERATOR.
STEP 2: STEP 2 AFTER STEAM GENERATOR HAS COMPLETELY DRAINED REPEAT
STEP 3: STEPS 1 & 2 OF DAILY OPERATING PROCEDURE.(WATER TO REMAIN IN STEAM

GENERATOR UNTIL NEXT DAILY USE.)

CONTROL PANEL:

MODELS: • M24E24A

• M24E36A

• M24E42/48A

• M36E24A

• M36E36A

• M36E42/48A

OPERATING THE STEAM GENERATOR:

OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS

6

ADJUSTMENTS

WARNING:

Because power must be on to adjust pressure switches, be sure to protect against electrical shock.

SETTING THE BOILER CONTROL PRESSURE SWITCHES:

PRESSURE CONTROL SWITCH ADJUSTMENT:

If boiler fails to maintain steam pressure in operating range, pressure control switch may require
adjustment.

1. Start boiler and allow pressure to build up to operating level - 15 PSI (1kg/cm²).

2. Check boiler pressure gauge. If gauge indicates 12 to 14 PSI, pressure control switches are

properly adjusted.

3. If boiler does not come on when pressure gauge reads 7 PSI and does not go off when pressure

gauge reads 14 PSI, proceed as follows:

a) Remove screw and lift front cover off control box.
b) Hand adjust operating pressure control switch and high limit pressure control switch by turning

adjusting nut (Knurled knob) clockwise to raise and counter clockwise to lower actuation point.
Switch should be set so that boiler comes on when boiler pressure gauge reads 12 PSI and goes
off when gauge reads 14 PSI. Switch should be set so that boiler will shut off if pressure reaches
15 PSI.

c) The actuation value (differential) is factory set and cannot be changed.
d) The cold water condenser thermostat is preset at factory.
e) Repeat steps, 1, 2, and 3. If 12 to 14 PSI boiler pressure gauge reading is obtained during boiler

operation, adjustment is correct. If proper adjustment cannot be made consult Trouble­Shooting Guide in this manual.

f) After making adjustments, replace cover on pressure switch box and screw.

7

GENERAL TROUBLE SHOOTING

TROUBLE

POSSIBLE CAUSE

REMEDY

Water does not enter the
boiler.

a. Water main shut-off.
b. Power not reaching unit.
c. Probes dirty.
d. Water level control board

defective.

e. Solenoid valve defective.

a. Turn on.
b. Check main fuse or circuit.
c. Remove and clean.
d. See (page 9) for test procedure.
e. If 120V is verified at solenoid

coil, but fails to open, replace
solenoid.

Boiler fails to build up
pressure when water level
is proper and fuel switch is
turned on.

a. Check to see that circuit

breaker in main is turned on.

b. Check to see that contactors

are pulling in.

c. Current flow is broken at

water level control (ascertain
with continuity check).

d. Current flow is broken at

pressure control or high limit
control switches due to
maladjustment or defect
(ascertain with continuity
check).

e. Heating elements are

defective.

a. Check for voltage at terminal

block.

b. Check continuity of coil, if open

replace.

c. Check for voltage at L1 and L2,

replace if defective.

d. Readjust - to proper setting -

refer

b. to instructions for

readjustment, replace if
defective.

c. 5. Replace if continuity check

through the circuit of each
element shows defective.

Boiler fails to reach full
operating pressure of 5
lbs. or 15 lbs.

a. Pressure gauge reads

inaccurately.

b. Pressure control and high limit

control switches are out of
adjustment.

c. Safety valve not seating

properly.

d. Contactor coils (one or both)

not energizing and closing
circuit to the heating
elements.

a. Replace.
b. Follow instructions for

readjusting or replace if
defective.

c. Clean or replace.
d. Check - replace either

contactor coils or complete
contactor – if found defective.
Measure amperage at terminal
block check to be sure there is
an even draw on all three
phases - see wiring diagrams
for correct AMP draw. If
uneven or zero amperage draw
is found on one of the three
phases, check for blown fuse. If
fuse is OK, shut off power,
remove wires from heating
elements and run continuity
check - replace if defective.

GENERAL TROUBLE SHOOTING

8

TROUBLE

POSSIBLE CAUSE

REMEDY

Water enters boiler very
slowly.

a. Dirty Strainer screen in

solenoid valve.

a. Clean or replace strainer screen,

part no. 08-4871.

Water level in gauge glass
fluctuates up and down.

a. Top shut off on water gauge is

closed.

a. Open.

Contactor chatters.

a. Incorrect supply voltage.
b. Dirty or worn contactor points.
c. Weak coil.

a. Check to see that it matches it

with coil contactors.

b. Clean or replace contactor.
c. Replace with correct voltage

coil.

15 lbs. safety valve blows
off prematurely.

a. Pressure set too high.
b. Pressure gauge reads

incorrectly.

c. Mineral build-up or dirt on

seat of valve.

d. Weak spring valve.

a. Readjust.
b. Replace.
c. Clean.
d. Replace valve.

Boiler build up to
pressure, shuts down and
fails to come on.

a. High limit switch set too low

or operating pressure control
switch set too high.

a. Follow instructions for

readjusting, (see page 6), or
replace if defective.

Air vent leaking.

a. Not closing.

a. Replace.

Cold water condenser
does not function.

a. Main water line shut off.
b. Thermostat defective.
c. Tighten coil nut.
d. Check solenoid coil for

continuity, if open replace.

a. Turn on.
b. Replace if defective.
c. Tighten coil nut.
d. Check coil for continuity, if

open replace.

Product in cooker does
not cook properly on first
cycle, but cooks alright
after first cycle is
exhausted.

a. Air vent is closing.

a. Replace.

Contactor chatters.

a. Low voltage.
b. Defective or incorrect coil.

a. Check voltage condition. Check

momentary voltage dip during
starting. Low voltage prevents
magnet sealing. Check coil
voltage rating.

b. Replace coil, rating of coil must

match the line voltage.

Welding or freezing.

a. Abnormal spike in current.
b. Low voltage preventing

magnet from sealing.

c. Short circuit.

a. Check for grounds or shorts in

system.

b. Correct voltage condition.
c. Remove short fault and check

to be sure fuse or breaker size
is correct