Market Forge M24E32A Installation Manual
ELECTRIC OPERATED BOILER
INSTALLATION, OPERATING, MAINTENANCE AND PARTS MANUAL
MODELS:
□ M24E24A □ M24E32A □ M24E36A
□ M24E42A □ M24E48A □ M36E24A
□ M36E24A □ M36E32A □ M36E36A
□ M36E42A □ M36E48A
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 FLAMMABLE VAPORS AND LIQUIDS IN
THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
POST INSTRUCTIONS IN A PROMINENT LOCATION TO BE FOLLOWED IN THE EVENT
THE USER SMELLS GAS. THIS INFORMATION SHALL BE OBTAINED BY CONSULTING
THE LOCAL GAS SUPPLIER.
Printed in U.S.A.
Form No S-3112 Rev. D
35 Garvey Street, Everett, MA 02149
Tel: (617) 387-4100, (866) 698-3188, Fax: (617) 387-4456, (800) 227-2659
custserv@mi.com, www.mi.com
TABLE OF CONTENTS
____________________________________________________________________________
○ INTRODUCTION .............................................................................................................. i
▪
TO THE KITCHEN MANAGER .................................................................................... i
▪ INTRODUCTION .......................................................................................................... i
▪ HOW TO USE THIS MANUAL .................................................................................... i
▪ THEORY OF OPERATION FOR ELECTRIC BOILER ................................................. i
○ INSTALLATION INSTRUCTIONS .................................................................................... 1-2
▪ ELECTRIC OPERATED BOILERS .............................................................................. 1
▪ RECEIVING INSTRUCTIONS ...................................................................................... 1
▪ INST
▪ LEVELING ................................................................................................................... 1
▪ SER
○ OPERATING INSTRUCTIONS ......................................................................................... 3
▪ OPERA
▪ DAIL
▪ DAIL
ALLING LEGS ...................................................................................................... 1
VICE CONNECTIONS ......................................................................................... 2
TING INSTRUCTIONS FOR STEAM GENERATORS ..................................... 3
Y OPERATING PROCEDURE ............................................................................. 3
Y SHUT DOWN AND CLEANING ........................................................................ 3
○ ADJUSTMENTS ............................................................................................................... 4-5
▪ IF GAS PRESSURE IS LOW ....................................................................................... 4
▪ IF GAS PRESSURE IS
▪ SETTING OR BOILER CONTROL
▪ PRESSURE CONTROL SWITCH ADJUSTMENT ...................................................... 5
○ ELECTRICAL INFORMATION .......................................................................................... 6-12
○ MAINTENANCE ...............................................................................................................13-14
○ APPLICATION INSTRUCTIONS ......................................................................................15-16
○ GENERAL TROUBLE-SHOOTING GUIDE .......................................................................17-20
○ ILLUSTRATED PARTS LIST .............................................................................................21-27
▪ BOILER BASE CABINET ............................................................................................. 21
▪ PRESSURE SWITCH BOX WITHOUT COVER .......................................................... 22
▪ CONTROL BOX ASSEMBLY WITH AND WITHOUT COVER ..................................... 23
▪ SIDE VIEW, ELECTRIC BOILER ................................................................................ 24
▪ FRONT VIEW, ELECTRIC BOILER ............................................................................. 25
▪ CONTACTOR BOX WITHOUT COVER ...................................................................... 26
▪ ELEMENTS ................................................................................................................. 27
TOO HIGH .............................................................................. 4
PRESSURE SWITCHES ...................................... 5
INTRODUCTION
____________________________________________________________________________
TO THE KITCHEN MANAGER:
Read this manual carefully and in its entirety. Contact Market Forge Ind., Inc. for clarication
1.
if necessary.
Protect your kitchen personnel from scalding and other serious injury by providing training
2.
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 equip-
4.
ment, no matter who the
manufacturer, is inherently dangerous when misused. The possibility of serious scalding al-
5.
ways exists, the careless and/or untrained operator will be injured.
This equipment must be maintained according to the guidelines in this manual (see “mainte-
6.
nance”). Lack of maintenance
will lead to a potentially hazardous condition and possible liability. Operators should report
7.
any equipment malfunction immediately and steps must be taken to correct the problem be-
fore further use of the equipment is allowed.
Keep this manual for daily reference.
8.
INTRODUCTION:
Market Forge, in the interest of both cost and efciency 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 capac-
ity dictate a divergence from this policy for more efciency 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 identication, 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 lled 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.
i
INSTALLATION INSTRUCTIONS
____________________________________________________________________________
MODELS:
□ M36E42A □ M36E48A
WARNING: READ THIS BEFORE OPEING THE SHIPPING CONTAINERS !!!!!!!!
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. Mar-
ket 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:
Count the number of cartons and packages received to be sure they coincide with the bill of
1.
lading.
□ M24E24A □ M24E32A □ M24E36A □ M24E42A
□ M24E48A □ M36E24A □ M36E32A □ M36E36A
Visually check all cartons for external damage.
2.
Remove all cartons from their skids to examine equipment for concealed damage. The carton
3.
is nailed and strapped to the skid. It will be necessary to cut the straps and pry off the container.
After inspection, replace the cartons over the equipment on the skids to protect and secure
4.
the equipment until it is ready for installation.
Sign for shipment if all is in order. Note shortages, external and concealed damage, if any, on
5.
the bill of lading before accepting a partial or damaged shipment.
If necessary, contact the carrier immediately to le a claim. All claims must be led by the
6.
receiver.
Do not remove the cartons or the skids from the cooking equipment until the unit has been
7.
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.
1
INSTALLATION INSTRUCTIONS
____________________________________________________________________________
SERVICE CONNECTIONS
Electrically Operated
EP Power Supply - Use wire suitable for at least 90°C. Nominal amp per line wire:
Volts 24 kW 32 kW 36 kW 42 kW 48 kW
3 pH 3 pH 3 pH 3 pH 3 pH
208 (197-219)
240 (220-240)
480 (360-500)
Details of other electrical systems available upon request.
CW1 Cold Water - 3/8” (10mm) NPT for cold water to boiler. Cold water lines will have a
maximum of 50 PSI (3.5kg/cw
sure.
CW2 Cold Water - 3/8” (10mm) NPT for cold water to condenser. Cold water lines will have
a maximum of 50 PSI (3.5kg/cw
sure.
D Drain - Pipe full 2” (50mm) I.P.S. to ush oor drain capable of receiving water owing
at a maximum 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.
66
60
32
2
) and a minimum of 25 PSI (1.8 kg/cw2) water pres-
2
) and a minimum of 25 PSI (1.8 kg/cw2) water pres-
89
77
39
100
91
47
117
-
-
116
58
-
WARNING:
DO NOT UNDER ANY CIRCUMSTANCE
CONNECT THE EXHAUST DRAIN LINE
DIRECTLY TO A SEWER LINE.
NOTES: If equipment is installed where elevation ex-
ceeds 2,000 feet (609.6 meters) above sea level, specify
installation altitude so that proper gas orices can be pro-
vided.
The only available space to supply utilities to the gas boiler
is the 6” (152mm) space between the oor and the cabinet. Allow 3” (76mm) space from side wall and 6” (152mm)
from real wall if adjoining walls are combustible.
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. EQUIP-
MENT FAILURE CAUSED BY INADEQUATE WATER
QUALITY IS NOT COVERED UNDER WARRANTY.
DRAIN 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 situ-
ated in a tiled oor 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 oor drain. If it is necessary
to use more than three elbows, increase the size of the
waste line accordingly.
NOTE: PVC & CPVC PIPE ARE NOT
ACCEPTABLE MATERIALS FOR DRAINS.
2
OPERATING INSTRUCTIONS
____________________________________________________________________________
MODELS:
□ M36E42A □ M36E48A
□ M24E24A □ M24E32A □ M24E36A □ M24E42A
□ M24E48A □ M36E24A □ M36E32A □ M36E36A
CONTROL PANEL
OPERATING INSTRUCTIONS
STEAM GENERATOR
● FIRST CHECK TO BE SURE THAT:
A.
WATER SWUTCH IS IN THE OFF POSITION.
B.
WATER SUPPLY VALVE IS OPEN.
C.
ELECTRICITY IS CONNECTED TO ALL UNITS.
D.
THAT THE GAS IS TURNED ON (GAS OPERATED UNITS ONLY).
E.
THEN PROCEED EITH 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 PRESS WATER SWITCH OFF. THIS WILL DRAIN THE STEAM GENERATOR.
STEP 2 AFTER STEAM GENERATOR HAS COMPLETELY DRAINED REPEAT
STEPS 1 & 2 OF DAILY OPERATING PROCEDURE.
(WATER TO REMAIN IN STEAM GENERATOR UNTIL NEXT DAILY USE)
3
ADJUSTMENTS
____________________________________________________________________________
A. IF GAS PRESSURE IS LOW:
Check your gas supply line for a restriction. If no restriction exists, check with your Natural
gas supplier to provide at least 5” of water column pressure in the gas supply line. If no
restriction exists and Propane gas is being used, the tank pressure regulator should be adjusted to supply at least 11” of water column pressure in the gas supply line. If this adjust-
ment cannot be made to your satisfaction, the gas supplier should be notied.
B. IF GAS PRESSURE IS TOO HIGH:
Adjust the pressure regulator on the boiler gas valve to reduce the pressure if Natural gas
is being used. If Propane gas is being used, adjust the pressure regulator supplied by the
gas supplier. If the regulator cannot be adjusted, notify the gas supplier.
4
ADJUSTMENTS
____________________________________________________________________________
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.
Start boiler and allow pressure to build up to operating level - 7 PSI (1kg/cm²).
1.
Check boiler pressure gauge. If gauge indicates 5 to 7 PSI, pressure control switches
2.
are properly adjusted.
If boiler does not come on when pressure gauge reads 7 PSI and does not go off when
3.
pressure gauge reads 7 PSI, proceed as follows:
WARNING: Because power must be on to adjust pressure switches, be sure to protect against
electrical shock.
Remove screw and lift front cover off control box.
a)
Hand adjust operating pressure control switch and high limit pressure control switch by
b)
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 5 PSI and goes off when gauge reads 7 PSI. Switch should be set so that
boiler will shut off if pressure reaches 15 PSI.
The actuation value (differential) is factory set and cannot be changed.
c)
The cold water condensor thermostat is preset at factory.
d)
Repeat steps, 1, 2, and 3. If 5 to 7 PSI boiler pressure gauge reading is obtained dur-
e)
ing boiler operation, adjustment is correct. If proper adjustment cannot be made con-
sult Trouble-Shooting Guide in this manual.
After making adjustments, replace cover on pressure switch box and screw.
f)
5
ELECTRICAL INFORMATION
D
94 - 5045 C
____________________________________________________________________________
WIRING DIAGRAM FOR NEW GENERATION BOILER
6
D
94 - 5045 C
ELECTRICAL INFORMATION
____________________________________________________________________________
WIRING SCHEMATIC FOR NEW GENERATION BOILER
7
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