Market Forge M36E18A User Manual

ELECTRIC OPERATED BOILER

INSTALLATION & OPERATING MANUAL

MODELS:

m M24E18A m M24E24A m M24E32A
m M24E36A m M24E42A m M24E48A
m M36E18A m M36E24A m M36E32A
m M36E36A m M36E42A m 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.

An Employee Owned Company

Printed in U.S.A.

Tel: [phone] l Fax: [phone] (Ex. MA) l [phone] (MA and Overseas)

S-3112 Rev.C 08/05 E-Mail: [e-mail] l Website: www.mfii.com

35 Garvey Street l Everett l MA l 02149

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.

INTRODUCTION:

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.

ii

INSTALLATION INSTRUCTIONS



ELECTRIC OPERATED BOILERS

MODELS:

  m M24E18A m M24E24A m M24E32A
  m M24E36A m M24E42A m M24E48A
  m M36E18A m M36E24A m M36E32A
  m M36E36A m M36E42A m 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. 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.

Page 1

SERVICE CONNECTIONS

SERVICE CONNECTIONS

Electrically Operated

Power Supply - Use wire suitable for at least 90°C.

EP

Nominal amp per line wire:

Details of other electrical systems available upon request.
Cold Water - 3/8" (10mm) NPT for cold water to boiler.

CW1

Cold water lines will have a maximum of 50 PSI
(3.5kg/cw
pressure.

Cold Water - 3/8" (10mm) NPT for cold water to condenser.

CW2

Cold water lines will have a maximum of 50 PSI (3.5kg/cw
and a minimum of 25 PSI (1.8 kg/cw

Drain - Pipe full 2" (50mm) I.P.S. to flush floor drain capable

D

of receiving water flowing at a maximum rate of 5 gallons
(19 liters) per minute. DO NOT MAKE SOLID CONNECTION
TO FLOOR DRAIN.

Volts 18KW 24KW 32KW 36KW 42KW 48KW
208 (197-219) 86 5 0 6 89 100 1 17 -

240 (220-240) 75 3 2 60 77 91 - 116
480 (360-500) 36 2 2 32 39 47 - 58

2

) and a minimum of 25 PSI (1.8 kg/cw2) water

1ph 3ph 3ph 3ph 3ph 3ph 3ph

2

) water pressure.

2

)

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.

Steam Take-off - Connection for operation of adjacent

ST

steam powered equipment.

NOTES: 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.

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.

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.

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 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.

Page 2

OPERATING INSTRUCTIONS

MODELS:

  m M24E18A m M24E24A m M24E32A
  m M24E36A m M24E42A m M24E48A
  m M36E18A m M36E24A m M36E32A
  m M36E36A m M36E42A m M36E48A

Control Panel

OPERATING INSTRUCTIONS

STEAM GENERATOR

m FIRST CHECK TO BE SURE THAT:
A. W ATER SWITCH IS IN THE OFF POSITION.
B. W ATER 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 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 PRESS WATER SWITCH OFF. THIS WILL DRAIN THE STEAM GENERATOR.
STEP 2 AFTER STEAM GENERATOR HAS COMPLETELY DRAINED REPEAT

STEPS 1 & 2 OF DAIL Y OPERATING PROCEDURE.
(WATER TO REMAIN IN STEAM GENERATOR UNTIL NEXT DAILY USE.)

Page 3

GENERAL TROUBLE SHOOTING GUIDE

TROUBLE

Water does not enter the boiler.

Water enters boiler very slowly.

Water level in gauge glass fluctuates

up and down.

Boiler fails to build up pressure when

water level is proper and fuel switch is

turned on.

POSSIBLE CAUSE

1. Water main shut-off.

2. Power not reaching unit.

3. Probes dirty.

4. Water level control board defective.

5. Solenoid valve defective.

1. Dirty strainer screen in solenoid
valve.



1. Top shut off on water gauge is
closed.

1. Check to see that circuit breaker in
main is turned on.

2. Check to see that contactors are
pulling in.

3. Current flow is broken at water
level control (ascertain with
continuity check).

REMEDY

1. Turn on.

2. Check main fuse or circuit.

3. Remove and clean.

4. See (page 8) for test procedure.

5. If 120V is verified at solenoid coil,
but fails to open, replace solenoid.



1. Clean or replace strainer screen.
Part No. 08-4871

1. Open.

1. Check for voltage at terminal block.

2. Check continuity of coil, if open

replace.

3. Check for voltage at L1 and L2,

replace if defective.

Boiler fails to reach full operating

pressure of 5 lbs. or 15 lbs.

4. Current flow is broken at pressure
control or high limit control switches
due to maladjustment or defect
(ascertain with continuity check).

5. Heating elements are defective.

1. Pressure gauge reads inaccurately.

2. Pressure control and high limit
control switches are out of
adjustment.

3. Safety valve not seating properly.

4. Contactor coils (one or both) not
energizing and closing circuit to the
heating elements.

4. Readjust - to proper setting - refer
to instructions for readjustment,
replace if defective.

5. Replace if continuity check through
the circuit of each element shows
defective.

1. Replace.

2. Follow instructions for readjusting
or replace if defective.

3. Clean or replace.

4. 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.

Page 4

GENERAL TROUBLE SHOOTING GUIDE (con't)

TROUBLE

Contactor chatters.

15 lbs. safety valve blows off

prematurely.

Boiler build up to pressure, shuts

down and fails to come on.

Airvent leaking.

Cold water condenser does not

function.

POSSIBLE CAUSE

1. Incorrect supply voltage.

2. Dirty or worn contactor points.

3. Weak coil.

1. Pressure set too high.

2. Pressure gauge reads incorrectly.

3. Mineral build-up or dirt on seat of
valve.

4. Weak spring valve.

1. High limit switch set too low or
operating pressure control switch
set too high.

1. Not closing.

1. Main water line shut off.

2. Thermostat defective.

REMEDY

1. Check to see that it matches it with
coil contactors.

2. Clean or replace contactor.

3. Replace with correct voltage coil.

1. Readjust.

2. Replace.

3. Clean.

4. Replace valve.

1. Follow instructions for readjusting,
see (page 7), or replace if defective.

1. Replace.

1. Turn on.

2. Replace if defective.

Product in cooker does not cook
properly on first cycle, but cooks

alright after first cycle is exhausted.

Contactor chatters.

Welding or freezing.

3. Tighten coil nut.

4. Check solenoid coil for continuity, if
open replace.

1. Airvent is closing.

1. Low voltage.

2. Defective or incorrect coil.

1. Abnormal inrush of current.

2. Low voltage preventing magnet
from sealing.

3. Short circuit.

3. Tighten coil nut.

4. Check coil for continuity, if open
replace.

1. Replace.

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

2. Replace coil, rating of coil must
match the line voltage.

1. Check for grounds or shorts in
system.

2. Correct voltage condition.

3. Remove short fault and check to be
sure fuse or breaker size is correct.

Page 5

GENERAL TROUBLE SHOOTING GUIDE (con't)

TROUBLE

Short contact button life and / or

overheating of contacts.

TROUBLE

POSSIBLE CAUSE

1. Filling or dressing.

2. Interrupting excessively high
current.

3. Discolored contacts caused by
insufficent contact pressure, loose
connection, etc.

4. Dirt or foreign matter on contact
surface.

5. Short circuit.

COILS

POSSIBLE CAUSE

REMEDY

1. Do not file silver tips. Rough spots
or discoloration will not harm tips or
impair their efficiency.

2. Check for grounds, shorts or
excessive current.

3. Check contact carrier for
deformation or damage, clean and
tighten connections.

4. Clean with Acetone.

5. Remove fault and check to be sure
fuse or breaker size is correct

REMEDY

Open circuit.

Overheated Coil.

1. Mechanical damage.

2. Burnt-out coil due to overvoltage or
defect.

1. Over-voltage or high ambient
temperature.

2. Wrong coil.

3. Shorted turns caused.

4. Under voltage, failure of magnet to
seal in.

1. Handle and store carefully. Do not
handle coils by the leads.

2. Replace coil.

1. Check application and circuit.

2. Check rating (voltage and
frequency) if incorrect, replace with
proper coil.

3. Replace coil.

4. Correct system voltage. Install new
coil.

Page 6