Market Forge M24E36A Service 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: [phone], Fax: [phone]

custserv@mi.com, www.mi.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 clarication

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 efciency 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 efciency 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 identication, 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 orices 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 notied.

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

ELECTRICAL INFORMATION

____________________________________________________________________________

WIRING DIAGRAM, SINGLE PHASE

8

ELECTRICAL INFORMATION

____________________________________________________________________________

ALTERNATE WIRING 480V - AFTER 10/01/05

9

ELECTRICAL INFORMATION

____________________________________________________________________________

ALTERNATE WIRING 480V - AFTER 10/01/05

10

ELECTRICAL INFORMATION

____________________________________________________________________________

WIRING DIAGRA, 18 kW - 24 kW - 32 kW

11

ELECTRICAL INFORMATION

____________________________________________________________________________

WIRING DIAGRA, 36 kW - 42 kW - 48 kW

12

MAINTENANCE

____________________________________________________________________________

STEAM GENERATOR

Market Forge Industries has two types of steam generators; one has an automatic drain; the
other a manual one. Automatic boilers are also capable of being drained manually. To determine
which one you have, refer to the daily operating instruction plate located behind the cabinet door,
which will identify the steam generator as being automatic or manual.

CLEANING GENERATOR

Market Forge Industries recommends that all generators be cleaned periodically due to the im-

purities which are introduced through the water supply. All water supplies contain some mineral
deposits and impurities, and the degree varies due to geographical location. Market Forge has
recommended a schedule of cleaning that should sufce to keep boilers in proper working order
where water supply is relatively pure. However, as no water supply in one area can be accurately
compared with that of another, this schedule should not be regarded as a fool proof formula to

prevent rust, scale, lime and foreign deposits from forming. A stepup of the recommended man­ual cleaning schedule becomes necessary where introduced impurities exist.

MAJOR CLEANING

The cleaning schedule should be performed two or more times per year as determined by local
water conditions. Market Forge recommends that use of its Cathodic Descaler to protect the inner
generator walls and components against rust, scale and lime deposits. The schedule to change
the Cathodic Descaler may be timed to the major cleanings or accelerated where impurities
prove to be excessive. The normal effectiveness of the descaler is one year.

Qualied Market Forge Service Agencies are available to establish a suitable schedule for major
cleanings and / or Cathodic Descaler replacements. Should you prefer, however, to make these
cleanings yourself, the instructions that follow are meant to assist you. These instructions are
generalized to apply to all models.

REPLACEMENT PARTS NEEDED TO COMPLETE THESE INSTRUCTIONS

NUMBER REQUIRED DESCRIPTION PART NUMER

1
1
1
1

10

For Best Results Market Forge Recommends the use of Total Concept (Refer to S-2299A) See
page 00.

CLEANING INSTRUCTIONS

Shut the HEAT and POWER switch by putting these switches in the off position. NOTE:

1.

Turn off the electric POWER SUPPLY VOLTAGE at the main switch to break all electrical

contact from the entire unit.

ON ALL BOILERS - DISCONNECT THE 115 VOLT CONTROL CIRCUIT

WHEN CLEANING THIS APPLIANCE, DO NOT HOSE DOWN

Access Cover Gasket (8”) Blr.
Access Cover Gasket (12” ) Blr.
Set of Rubber and Brass Washers
Market Forge Cathodic Descaler
Sealing Washer

WARNING:

IMPORTANT:

ELECTRICAL PARTS INSIDE.

91-8756
98-1673
90-0039
08-0034

10-2455

On manual generators it is necessary to also open the generator drain valve to allow the

2.

generator to empty. Leave open.

13

MAINTENANCE

____________________________________________________________________________

Remove the access cover as follows: With a socket ratchet type wrench turn the 1 / 4 - 20

3.

hex nut counterclockwise. Remove the access cover taking care while handling with the
heating elements attached.

Clean rust, scale and lime deposits from the inside of the generator with a wire brush.

4.

DO NOT DAMAGE COPPER HEATING ELEMENTS - BRUSH LIGHTLY. WORK DEPOSITS
TO REAR CORNER AND REMOVE WITH PUTTY KNIFE.

When satised that the cleaning of the inside of the generator has been accomplished, ush

5.

out with water. Introduce the water through the access cover and allow it to drain through the
open boiler drain valve.

Clean the access cover with the wire brush and wash. Make sure the areas that will contact

6.

the gasket surface is well cleaned.

Remove old descaler. Install a new Market Forge Cathodic Descaler. (If old descaler cannot

7.
be removed, see the following instructions a - f)

Select a place on the front of the access cover where the zinc anode may be installed without

a.

interference, and should have atleast 1 / 2” of water over the top.

Drill and tap a 3 / 4” NPT (see Figure 1)

b.

Clean the acccess cover area where the zinc anode will be in contact with the plate CLEAN

c.

TO BARE METAL!
Install new 3 / 4” NPT Brass tting and zinc anode. (see Figure 1)

d.

The zinc anode must be completely covered with water to a minimum depth of 1 / 2”.

e.

Remove metal chips from generator after drilling and tapping.

f.

Re - install the access cover using a new gasket and staggered tightening measures until

8.
boiler is pressurized, then make your nal tightening.

Figure 1. Figure 2.

Clean the water gauge glass as follows:

9.

Unscrew the two valve ttings from both valves until they will be free to slide up and down the

a.

gauge glass. Grasp the water gauge glass and push downward toward the lower valve. This
action will compress the rubber washer at the lower valve and allow the water glass ample
clearance to be drawn free at the upper valve.

Slide off and discard the two rubber and brass washers and slip off the two valve ttings.

b.

Clean the water gauge glass (A small bottle brush is ideal for this purpose).
Reinstall by reversing the above steps. Install new rubber and brass washers for best re-

c.

sults.

Inspect probes for cleanliness (located at the top of the shell). If there is any build up on the

10.

probes, you may experience false readings. To clean the probes you may use some steel
wool to remove deposits. After assuring that the probe assembly is clean, you may fasten the
plate back into position. Your boiler is now ready for use!

14

APPLICATION INSTRUCTIONS

____________________________________________________________________________

APPLICATION INSTRUCTIONS FOR TOTAL CONCEPT CLEANING OF BOILER

SIZE: 1 Gallon PART NUMBER: 20 - 0307

GENERAL NOTES:

Market Forge R has two basic types of boilers; one

has an automatic drain valve, the other has a man-

ual drain valve. To determine which type you have,
open cabinet doors and you will see a control box

with two switches and an indicator light. The instruc-

tion label on the control box will identify the boiler
as being either automatic or manual. Those boilers
designated as being automatic must be energized

in order to close the drain valve.

Total Concept is designed to be used with water be-

tween 160°F to 200°F.

Fig. 2

Preheating is required on both automatic and man­ual boilers to raise the water temperature to the ac-

ceptable range. (160°F to 200°F).

For manual boilers, make certain drain valve is
tightly closed.

On Market Forged boilers manufactured after 8/84;
your unit is equipped with an access plug in the
steam header line. This location should be used
to add cleaner/descaler to boiler chamber during

maintenance.

On Market Forged boilers manufactured before
8/84; access to boiler chamber should be gained
through either the vent-rite or the pressure relief

valve.

Total Concept is a NSF listed nonfood product. This
is a liquid acid (nonmuriatic) product that works
without fumes, odors, and hazards associated with

other harsh chemicals.

BOILER TREATMENT CLEANING INSTRUC­TIONS:

After determining proper location for cleaner/des­caler to be added: Read complete instructions thor­oughly; including all warning and cautionary state-

ments.

Fig. 1

2. Energize heating circuit to pre-heat unit.

Fig. 3

Fig. 4

3. AUTOMATIC - After unit is pre-heated, cycle the

power switch to the OFF position then immedi-

ately back to the ON position.

1. Energize boiler and ll to operating level.

4. Remove the shipping cap, replace it with the
pouring cap. Cut the tip of the pouring cap at the
rst notch to a 45o angle.

15

APPLICATION INSTRUCTIONS

____________________________________________________________________________

APPLICATION INSTRUCTIONS FOR TOTAL CONCEPT CLEANING OF BOILER

SIZE: 1 Gallon PART NUMBER: 20 - 0307

Fig. 5

5. Install the tubing rmly over the tip of the pouring
cap.

Fig. 6

6. Energize compartment to release steam pressure
in boiler to “0” PSI before removing pipe plug.

7. Remove the plug from the access port on the

steam header pipe inside cabinet doors.

8. Feed the tubing through the access port in the

boiler compartment. NOTE: A minimum of 12”
must be inserted.

Fig. 9

Tilt the container, pour the contents into the unit.

9.
When empty, rell the container with hot tap wa-

10.

ter and add to boiler for cleaning. Repeat twice.
This additional 2 gallons of water will cause the

low water probe to be immersed in cleaner/des-

caler solution. Replace access plug.

After rinsing the container, place tubing inside

11.

the bottle, cover with shipping cap, dispose of
properly. DO NOT REUSE CONTAINER.

CAUTION:

HE7DER PIPE & ACCESS PLUG ARE HOT.

Fig. 7

Fig. 8

16

DO NOT ENERGIZE HEATERS. Allow 2 hours

12.

for cleaning.

After time has elapsed, drain the boiler.

13.

Rell the boiler and drain. Repeat this step

14.

twice.

Bring the boiler to temperature and cycle steam

15.

to the cooker compartment to purge cleaner/
descaler from the steam supply lines. Repeat
this step twice.

Boiler is now ready for use.

16.

GENERAL TOUBLE SHOOTING GUIDE

____________________________________________________________________________

TROUBLE POSSIBLE CAUSE REMEDY

Water does not enter boiler. Water main shut-off.

Water enters boiler very slowly. Dirty strainer screen in sole-

Water level in gauge glass uctu-

ates up and down.

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

on.

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

Product in cooker does not
cook properly on rst cycle, but
cooks alright after rst cycle is

exhausted.

1.

Power not reaching unit.

2.

Probes dirty.

3.

Water level control board

4.
defective.

Solenoid valve defective.

5.

1. Clean or replace strainer
noid valve.

Top shut off on water gauge

1. Open.1.
is closed.

Check to see that circuit

1.

breaker in main is turned on.
Check to see that contactors

2.

are pulling in.
Current ow is broken at

3.

water level control (ascertain
with continuity check).

Current ow is broken at

4.

pressure control or high limit

control switches due to mal­adjustment or defect (ascer-

tain with continuity check).

Heating elements are defec-

5.
tive.

Pressure gauge reads inac-

1.
curately.

Pressure control and high

2.

limit control switches are out
of adjustment.

Safety valve not seating

3.

properly.

Contactor coils (one or both)

4.

not energizing and closing

circuit to the heating ele-

ments.

Airvent is closing.1. Replace.1.

Turn on.

1.

Check main fuse or circuit.

2.

3. Remove and clean.

3.
See (page 8) for test proce-

4.
dure.

If 120V is veried at sole-

5.

noid coil, but fails to open,
replace solenoid.

1.
screen.Part No. 08-4871

Check for voltage at terminal

1.

block.
Check continuity of coil, if

2.

open replace.
Check for voltage at L1 and

3.

L2, replace if defective.

Readjust - to proper set-

4.

ting - refer to instructions
for readjustment, replace if

defective.

Replace if continuity check

5.

through the circuit of each
element shows defective.

Replace.

1.
Follow instructions for read-

2.
justing or replace if defec­tive.

Clean or replace.

3.
Check - replace either con-

4.
tactor

coils or complete contactor

5.

- if found defective. Measure

amperage at terminal block
check to be sure there is an

even draw on all three phas-

es - 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.

17

GENERAL TOUBLE SHOOTING GUIDE

____________________________________________________________________________

TROUBLE POSSIBLE CAUSE REMEDY

Contactor chatters. Incorrect supply voltage.

15 lbs. safety valve blows off
prematurely.

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

Cold water condenser does not

function.

Airvent leaking. 1. Not closing.1. Replace.1.

Contactor chatters. Low voltage.

Welding or freezing. 1. Abnormal inrush of cur-

Short contact button life and / or
overheating of contacts.

1.

Dirty or worn contactor

2.

points.
Weak coil.

3.

Pressure set too high.

1.
Pressure gauge reads incor-

2.
rectly.

Mineral build-up or dirt on

3.
seat of valve.

Weak spring valve.

4.

1. High limit switch set too

1.

low or
operating pressure control

2.

switch set too high.

1. Main water line shut off.

1.
Thermostat defective.

2.

Tighten coil nut.

3.
Check solenoid coil for conti-

4.

nuity, if open replace.

1.
Defective or incorrect coil.

2.

1.
rent.

Low voltage preventing mag-

2.

net from sealing.

Short circuit.

3.

1. Filling or dressing.

1.

Interrupting excessively high

2.
current.

Discolored contacts caused

3.
by insufcent contact pres­sure, loose connection, etc.

Dirt or foreign matter on

4.
contact surface.

Short circuit.

5.

Check to see that it matches

1.

it with coil contactors.
Clean or replace contactor.

2.

Replace with correct voltage

3.
coil.

Readjust.

1.

Replace.

2.

Clean.

3.

Replace valve.

4.

Follow instructions for re-

1.

adjusting, See (page 7), or

replace if defective.

Turn on.

1.

Replace if defective.

2.

Tighten coil nut.

3.

Check coil for continuity, if

4.

open replace.

Check voltage condition.

1.

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

Replace coil, rating of coil

2.

must match the line voltage.

Check for grounds or shorts

1.
in system.

Correct voltage condition.

2.
Remove short fault and

3.

check to be sure fuse or
breaker size is correct.

Do not le silver tips. Rough

1.

spots or discoloration will
not harm tips or impair their
efciency.

Check for grounds, shorts or

2.
excessive current.

Check contact carrier for

3.

deformation or damage,

4.
clean and tighten connec­tions.

Clean with Acetone.

5.

Remove fault and check to

6.

be sure fuse or breaker size

is correct

18

GENERAL TOUBLE SHOOTING GUIDE

____________________________________________________________________________

COILS

TROUBLE POSSIBLE CAUSE REMEDY

Open circuit. Mechanical damage.

1.
Burnt-out coil due to over-

2.

voltage or defect.

Handle and store carefully.

1.

Do not handle coils by the

leads.

Replace coil.

2.

Overheated Coil. 1. Over-voltage or high am-

1.

bient temperature.
Wrong coil.

2.
Shorted turns caused.

3.

Under voltage, failure of

4.

magnet to seal in.

Check application and

1.
circuit.

Check rating (voltage and

2.
frequency) if incorrect, re-

place with proper coil.
Replace coil.

3.

Correct system voltage.

4.

Install new coil.

19

GENERAL TOUBLE SHOOTING GUIDE

____________________________________________________________________________

WATER CONTROL BOARD TESTING PROCEDURE

This test procedure is to be used

to determine if the control is work­ing properly. It is not intended to de-

termine why the control may have

failed.

If testing shows that the control is
operating properly, check all probe

and solenoid wiring and the condi-

tion of the electrodes in the steam

chamber.

Contact the factory if the boiler still

does not operate properly after com-

pleting the testing.

Tools Needed:

»

Digital or Analog V-O-M meter.

»

Alligator clip type test jumpers (2

sets min.).

Turn Off Power to Control:

»

Use V-O-M to verify there is no
power at terminals L 1 & L2.

»

Use V-O-M to verify that there is no
power at terminals ‘FW(NO)’, ‘LO
LlTE(NC)’ & ‘HTR(NO)’. If there is
power at any of these terminals,
you will need to nd the source and

turn it off.

Remove Wires from Probe and Re­lay Switch Terminals:

»

DO NOT remove wires from L 1 &
L2 terminals.

»

Tag wires and remove from probe

and relay contact terminals includ-

ing ‘GND’ terminal.

»

Tag and remove wires from ‘RE-

SET’ terminals.

»

Connect jumper wire to both ’RE-

SET’ terminals.

Turn Power On to Terminals L 1 &
L2:

»

‘LED l’ should turn on.

»

‘LED 2’ should be off.

»

‘LED 3’ should be off.

»

Use V-O-M to verify that there is
power at ‘FW(NO)’ & ‘LO LlTE(NC)’
terminals and no power ‘HTR(NO)’

terminals

Test Feedwater Function:

Connect jumper wire to ‘FW HIGH’

»

and ‘GND’ terminals.
‘LED l’ should turn off after a 10

»

second delay.

Use V-O-M to verify that there is no

»

power at the ‘FW (NO)’ terminal.
Remove jumper from ‘FW HIGH’

»

and

‘GND’ terminals. . ‘LED l’ should

»

turn on.

Use V-O-M to verify that there is

»

power at the ‘FW(NO)’ terminal.

Test Primary Low Water Function:

Connect jumper wire to ‘LW(1) and

»

‘GND’ terminals.
‘LED 3’ should turn on.

»

Remove jumper wire from ‘LW(1)’

»

and ‘GND’ terminals.

‘LED 3’ should turn off after a 3 sec-

»

ond delay.

Connect jumper wire to ‘LW(1)’ and

»

‘GND’ terminals.
‘LED 3’ should turn on.

»

IMPORTANT:

Jumper wire between ‘LW(1)

and ‘GND’ terminals must re-

main in place to test secondary

low water function.

Test Secondary Low Water
Fun tion:

Connect jumper wire to ‘LW(2)’ and

»

‘GND’ terminals.
‘LED 2’ should remain off.

»

Use V-O-M to verify that there is

»

power at the ‘LO LlTE(NC)’terminal

and no power at the ‘HTR(NO)’ ter-

minal.

Remove the jumper wires from the

»

‘RESET’ terminals.
‘LED 2’ should turn on.

»

Use V-O-M to verify that there is

»

no power at the ‘LO LlTE(NC)’ ter-

minal and power at the ‘HTR(NO)’

terminal.

Connect jumper wire to ‘RESET’

»

terminals.

Remove jumper wire from ‘LW(2)’

»

and ‘GND’ terminals.

‘LED 2’ should turn off after a 3 sec-

»

ond delay.

USE V-O-M to verify that there is

»

power at the ‘LO LlTE(NC)’ termi-

nal and no power at the ‘HTR(NO)’

terminal.

Connect jumper wire from ‘LW(2)’

»

and ‘GND’ terminals.
‘LED 2’ should remain off.

»

IF ANY OF THE FUNC-

TIONS DONOT WORK,

REPLACE THE BOARD!

IF ALL FUNCTIONS

WORK, TROUBLE

SHOOTING OTHER

COMPONENTS WILL

BEREQUIRED!

20

ILLUSTRATED PARTS LIST

____________________________________________________________________________

24” Boiler Base Cabinet

ITEM PART NO. DESCRIPTION

1 08-5894 Market Forge Nameplate Logo
2
3 98-399
3 98-3993 Panel, Front
4 10-0631 Leg, 6”
4
4 08-520
4
4 10-032
5 98-3968 T
6 98-3978 Glass
7
8 98-3994 Panel, Side
9 98-3995 Panel, Rear Assy, 24”
9 98-3996 Panel, Rear Assy, 36”

91-5795 Handle, Front

2 Panel, Front

08-5211 Leg, 10”

8 Leg, Flanged 6”

08-5206 Leg, 8”

6 Caster

98-3991 Gasket,

, 5”

rim, Edge

Adhesive

Assy, 24”
Assy, 36”

Assy

21

ILLUSTRATED PARTS LIST

____________________________________________________________________________

Pressure Switch Box

ITEM PART NO. DESCRIPTION

1 94-5064 Box, Pressure Switch
2 10-8410 Pressure Switch, Hi-Limit
3 10-841
4 98-3875 Switch, Drain By-Pass
5 08-7933 Manifold, Pressure Switches
6 10-4804 Pressure Gauge

1 Pressure Switch, Operating

22

ILLUSTRATED PARTS LIST

____________________________________________________________________________

Control Box Assembly (Electric Boilers)

ITEM PART NO. DESCRIPTION

1 08-6549 Switch, Power
2 94-5127 Switch, Manual Reset
3 10-5052 Light, Red
4 94-5003 Artwork, Control Box
5 08-6469 Fuse Holder
6 98-168
7 08-6472 Relay
8 08-6475 Relay Base
9

10

98-3877 Relay Bracket
08-6468 Fuse, 5A

0 Board, W

Tube

ater Level Control

23

ILLUSTRATED PARTS LIST

____________________________________________________________________________

36” Electric Boiler Base

ITEM PART NO. DESCRIPTION

1 10-0239 Hose, Drain
2 10-4137 Clamp, Hose
3
4 10-5234 Transformer
5 10-105
6 08-4822 V
7 08-7959 Hose, Condenser
8

9 98-140
10 10-0287 Hose, Drain
1

1 10-4137 Clamp, Hose
12
13
14
15 08-4900 Manual Valve, Water Inlet

91-6927 Box, Drain

8 V

98-3894 Copper Nozzle

1 V

08-7974 Clamp Hose
98-3914 Compression Fitting
10-4556 Air Vent

alve, Cold Water Condenser, 120V
alve, Boiler Feed

alve, Check

Assy.

24

ILLUSTRATED PARTS LIST

____________________________________________________________________________

36” Electric Boiler Base

ITEM PART NO. DESCRIPTION

1 10-1311 Valve, Drain, 120V
2 10-7955 Valve, Safety, 15PSI
3 98-1667 Cover, Front, Contactor Box
4 94-5065 Cover, Pressure Switch Box
5 08-5447 3/4” NPT, Brass Street Elbow
6 10-2728 Water Gauge Glass Ass’y

6a 10-4754 Water Gauge (Glass Only)

7 08-793
8 08-5427 3/4” Br

9 08-4991 3/4” Side Outlet
10 10-7943 3/4” Brass Union
11 10-1
12 10-3455 90

3 Pressure Switch Manifold

. Nipple, 2 1/2” Lg.

Tee

6 3/4” Nipple, 2” Brass

12

O

Elbow

25

ILLUSTRATED PARTS LIST

____________________________________________________________________________

Electric Boiler Contactor Box

ITEM PART NO. DESCRIPTION

1 98-1670 Box, Contactor

2

3

4 08-6553 Hi-Limit

5 10-5220 Ground Lug

6 08-7981 Terminal Strip

7 98-1663 Bracket, Contactor Mounting

8 98-401

10-5944 Contactor
98-1720 T

4 Bracket, Contactor

erminal Block

Thermostat

Tray

26

ILLUSTRATED PARTS LIST

____________________________________________________________________________

Electric Boiler Elements

ITEM PART NO. DESCRIPTION

1 98-1652 Plate, Front

2 98-1673 Gasket, Front Plate

3 91-8660 Gasket, Htg. Element
4a 08-6485 Heating Element, 9kW, 208 Volts

4b 08-6486 Heating Element, 9kW, 240 Volts

4c 08-6487 Heating Element, 9kW, 480 Volts (a.k.a 277 Volts)
4d 08-6415 Heating Element, 12kW, 208 Volts
4e 08-6416 Heating Element, 12kW, 240 Volts

4f 08-6417 Heating Element, 12kW, 480 Volts (a.k.a 277 Volts)

4g 08-6491 Heating Element, 14kW, 208 Volts

4

h 08-6418 Heating Element, 16kW

4j 08-6419 Heating Element, 16kW, 240 Volts

4k 08-6420 Heating Element, 16kW, 480 Volts (a.k.a 277 Volts)

5 08-6337 Water Level Probe

27

, 208 Volts