Market Forge MT-40, MT-60, MT-25 User Manual

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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-2110 REV. D 04/14
Printed in USA 35 Garvey Street, Everett, MA 02149

Telephone [phone], Fax [phone]

[e-mail], www.mfii.com

WARNING:

DO NOT UNDER ANY CIRCUMSTANCE CONNECT THE

EXHAUST DRAIN LINE DIRECTLY TO A SEWER LINE.

WARNING:

DO NOT HOSE DOWN UNIT AS IT MAY CONTAIN

ELECTRICAL COMPONENTS.

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 or filter system. EQUIPMENT FAILURE

CAUSED BY INADEQUATE WATER QUALITY IS NOT
COVERED UNDER WARRANTY.

Modular Tilting Direct Steam Jacketed Kettle

MODELS: □ MT-25

□ MT-40
□ MT-60

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Table of Contents

INTRODUCTION ......................................................... 1

INSTALLATION INSTRUCTIONS

SERVICE CONNECTIONS – MT-25EO, MT-40EO ......... 2

SERVICE CONNECTIONS – MT60EO ........................... 3

WIRING DIAGRAM ..................................................... 4

SCHEMATIC ................................................................ 5

OPERATING INSTRUCTIONS

START-UP ................................................................... 6

CONTROL PANEL ........................................................ 6

OPERATING THE STEAM BOILER ................................ 6

COOKING ................................................................... 7

INSTALL PAN SUPPORT .............................................. 8

SHUT-DOWN .............................................................. 9

DAILY CLEANING ........................................................ 9

COOKING GUIDE ................................................ 10-12

TROUBLESHOOTING .......................................... 13-15

ADJUSTMENTS

REPAIR & REPLACE ................................................... 16

PRESSURE CONTROL SWITCH ADJUSTMENTS ......... 16

COLD WATER CONDENSER ADJUSTMENT ............... 17

LID COUNTERBALANCE ADJUSTMENT ................ 17-18

HEATING ELEMENT REPLACMENT ........................... 18

WATER CONTROL BOARD TESTING PROCEDURE .... 19

WATER LEVEL CONTROL .......................................... 20

CIRCUIT OPERATION ................................................ 20

WATER LEVEL CONTROL OPERATION ...................... 20

LOW WATER CUTT OFF ............................................ 20

WATER LEVEL CONTROL MAINTENANCE AND

CLEANING ................................................................ 21

PROBE CLEANING .................................................... 21

DRAW OFF VALVE REPAIR ........................................ 22

COMMON LEAK REPAIRS ......................................... 22

VALVE SEAT LAPPING ............................................... 22

TILTING MECHANISM REPAIR .................................. 22

LIFT SCREW ASSEMBLY REMOVAL ........................... 22

GENERAL INSPECTION AND CLEANING .................... 23

CRANK SLEEVE REPLACEMENT ................................ 23

TILTING MECHANISM LUBRICATION ....................... 23

MAINTENANCE

PREVENTIVE MAINTENANCE ................................... 24

DAILY CLEANING ...................................................... 24

APPLICATION INSTRUCTIONS – TOTAL CONCEPT

DESCALER ............................................................ 25-26

ILLUSTRATED PARTS LIST

PRESSURE SWITCHES ............................................... 27

DRAIN ASSEMBLY ..................................................... 28

TILTING MECHANISM .............................................. 29

PISTON ASSEMBLY ................................................... 30

VALVE AND FAUCET ................................................. 31

LOW WATER CUT OFF .............................................. 32

CRANK SHAFT........................................................... 33

BOILER BASE ASSEMBLY .......................................... 34

ELECTRICAL COMPONENTS ...................................... 35

VALVE ASSEMBLY ..................................................... 36

KETTLE JACKET ASSEMBLY ....................................... 37

1

INTRODUCTION

This service and parts manual contains descriptive and maintenance information (including
trouble shooting guide) for modular kettles. A Parts list is also included in which each
replacement part is identified and shown in an accompanying illustration unless otherwise
stated.

Description:
Market Forge tilting direct steam jacketed kettles of three capacities, each mounted in a

modular stainless steel cabinet.

Double wall construction around the lower half of the kettle forms a surrounding chamber into
which steam is introduced as a source of heat for cooking.

Steam input plumbing is equipped with a manual control valve. Condensate is removed through
a steam trap connecting with the kettle drain plumbing assembly. A swivel spout, hot-cold
combination faucet provides a source of water for addition to the kettle for cooking and
cleaning.

An optional 12” spacer unit with faucet and sink may be used instead of the standard built-in
faucet.

Large capacity kettles are fitted with heavy duty tilting mechanisms operated by removable
hand crank. Each model is equipped with a pan support which maintains continuous alignment
of serving pans under the pouring spout at all levels of kettle elevation. Counterbalanced
hinged lids cover the kettles in the lowered position. All are plumbed for direct connection to a
remote steam source. An optional cold water circuit to the steam jacket is available for use with
all models for quick cooling of foods after cooking.

Applicable model designation includes: MT-25 (25-gallon) – 36” wide (914mm) cabinet base,
MT-40 (40-gallon) – 36” wide (914mm) cabinet base, and MT-60 (60-gallon) – 48” wide
(1219mm) cabinet base.

Service:

Required service, both repair, replacement, and adjustment is explained in Adjustments section
of this manual. Other service help can be found in the Trouble Shooting and Maintenance
sections of this manual. Should repairs be required, a network of Authorized Service Agents is
available to assist with prompt service. A current list of Authorized Service Agencies may be
obtained by contacting Market Forge direct of going on our website:

Call us toll free at [phone] or [phone]
Email us at [e-mail] or go to http://www.mfii.com/company/service

The model and serial number must be referenced when corresponding with Market Forge.
These numbers can be found on the data plate located on the upright frame behind the cabinet
base door. If you require further assistance in obtaining these numbers, please contact us
directly.

2

S

Steam Supply - 3/4” (19mm) NPT, 15 P.S.I
(1.0 kg/cm2) minimum; 30 P.S.I (2.1 kg/cm2)
maximum.

HW

Hot Water - 3/8” (10mm) OD tubing to hot
water for kettle fill faucet.

CW

Cold Water - 3/8” (10mm) OD tubing to cold
water for kettle fill faucet.

D

Drain - Pipe full 2” NPT (51mm) to flush floor
drain. Do not make solid connection to
drain.

CR*

Condensate Return - 1/2” I.P.S. (13mm)
connection for condensate return from
kettle when specified.

EC*

Electrical Controls - 115 volts AC, 60 Hz, 40
watts, 1/2” (13mm) conduit connection or
equivalent. Use wire suitable for at least
90OF. Draws less than 1 Amp with power lift.

* Optional.

MT-60

SERVICE CONNECTIONS:

MT-25 and MT-40

INSTALLATION INSTRUCTIONS

NOTES:

1. Pressure-reducing valve is required if incoming
pressure exceeds 30 PSI (2.1 kg/cm2).

2. Recess area for kettle draw-off (dotted line) must
be kept free of all piping and connections.

3. PVC and CPVC pipe are not acceptable materials for drains.

4. Separate height for 25-, 40-, and 60-gallon kettles.

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OPERATION INSTRUCTIONS

CAUTION: FOOD MUST EITHER BE REMOVED FROM THE KETTLE IMMEDIATELY OR COOLED BY
A KETTLE JACKET COOLING SYSTEM TO PREVENT OVER COOKING.

OPERATING CONTROLS & INDICATORS

All of the controls required to operate the kettles are listed in table on page 4, together with an
explanation of location and a short functional description.

OPERATING PROCEDURE

All kettles must be supplied with steam from a generator which is remotely located. Consult steam
generator information or instruction plate and complete all start-up instructions. Proceed with
kettle operating procedure as follows:

1. Check pressure gauge of steam supply source to insure steam input is at 15 PSI (1.0 kg/cm

For direct connected steam, turn on external steam supply valve.

2. Check that Draw-Off Valve is tightly closed.

3. Lift kettle lid and place either a Solid or Perforated Drain Disc over the drain inside kettle.

Use solid disc to retain liquids; perforated to strain liquids from food.

4. Load kettle with foods to be cooked.

5. Add water for cooking by swinging spout over kettle and using Combination Faucet.

6. Turn Steam Control Valve to full counter-clockwise position to heat kettle content to an

initial rapid boil.

7. Adjust subsequent cooking temperature by turning Steam Control Valve. Turn clockwise to

reduce heat and counter-clockwise to increase.

8. Close Steam Control Valve (full clockwise position) when cooking is complete.

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).

9. Remove food from tilting kettles. With Pan Support mounted (see section pan support

mounting tilting kettles, on page 4), food pan in support, and Crank installed in front of
cabinet, turn crank clockwise to elevate kettle for pouring. (Tilting mechanism is infinitely
adjustable and non-coasting in kettle elevation and lowering). Liquid foods may also be
removed by use of the Draw-Off Valve as explained in step 11 for stationary kettles.

10. Complete cleaning procedures (see cleaning procedure section below).

CLEANING PROCEDURE

As with cleaning food soil from any cookware, an important part of kettle cleaning is to prevent
foods from drying on. For this reason cleaning should be completed immediately after cooked
foods are removed. If time can not be allotted for immediate complete cleaning the kettle should
be soaked by filling it with warm detergent water solution.

Cleaning

1. Wash the kettle with a long handled nylon bristle kettle brush (Part No. 10-5308).

2. Empty wash water by opening Draw-Off Valve over Swing Drain.

3. Remove Drain Disc (solid or perforated) from inside kettle and clean.

4. Rinse kettle by flushing with hot water from the Swivel Spout.

5. Loosen hex nut on Draw-Off Valve and carefully remove all parts. Clean and reassemble (see

figure 11, on page 17).

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OPERATION INSTRUCTIONS

6. Rotate Swing Drain to left and push up off drain assembly. Clean drain and screen.

Reassemble on kettle.

Pan Support Mounting Tilting Kettles

For convenience during cooking, the pan support need not be installed until needed for removing
food from the kettles. To Insure correct operation and to prevent spills the support must be
securely installed as shown in Figure 1 below and as explained below:

1. Hold the pan support in front of the upright as shown at A.

2. Place the stud of the left-hand support upright into the hole in the left side of the pan

support. Then push the right side of the support in until it engages the spring loaded pin of
the right-hand support upright, shown at B.

3. Rotate the pan support upward (C) and engage the slotted ends of the support links in the

studs at the base of each support upright as in D.

The removal procedure is the reverse of installation with the exception that in step 2 support
upright springs must be pushed out to release the support from studs.

Figure 1, Mounting Pan Support

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Figure 2, Steam Jacketed Kettle

1 3 2

OPERATION INSTRUCTIONS

ITEM

PART NO.

DESCRIPTION

1

10-7680

HOT AND COLD FILL FAUCET

2

10-5242

STEAM CONTROL VALVE

3

98-1568

CRANK HANDLE (MANUAL TILT)

COOKING:

1. Check pressure to ensure that boiler is up to operational pressure of 10-12 PSI (0.7-0.8kg/cm

2. Check that draw-off valve is tightly closed by turning it

clockwise.

3. Place solid disc or perforated disc in drain opening

inside kettle.

NOTE: Use solid disc if liquid is to be retained; use
perforated disc if liquid is to be discarded.

4. Fill kettle to desired level with food to be cooked or

water from hot and cold fill faucet (Figure 2, No. 1).

NOTE: Refer to Cooking Guide (page 10) for cooking
procedures that address individual food products.

5. Turn kettle steam control valve (Figure 2, No. 2)

counterclockwise to full ON position for faster results.

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).

NOTE: The volume of steam going into the kettle jacket can be controlled at any time by adjusting
the kettle steam control valve in either direction.

6. When food is cooked, turn steam control valve clockwise to stop steam flow. Remove food

immediately to prevent over cooking.

7. Prior to removing foods from kettle, the pan support should be placed in a position to establish

a firm support for receiving pan.

DAILY CLEANING:

1. Fill kettle with water and mild detergent immediately after removing food from kettle.

2. Scrub kettle interior with a nylon brush.

NOTE: NEVER SCRAPE KETTLE INTERIOR WITH METAL TOOLS, STEEL SCOURING PADS OR ABRASIVE
CLEANERS. Scratches will result, which will ruin the kettles general appearance and make it harder to

clean and maintain in a sanitary condition.

3. Loosen food which is stuck to kettle by allowing it to soak. Also, a small amount of steam may

help.

4. Position swing drain under draw-off valve. Open draw-off valve to drain soapy water.

5. Wipe down exterior, rinse and dry. Avoid getting water into electrical controls.

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OPERATION INSTRUCTIONS

WARNING: DO NOT HOSE DOWN UNIT AS IT CONTAINS ELECTRICAL COMPONENTS.

6. Remove strainer from inside kettle. Wash and rinse thoroughly.

7. Disassemble draw-off valve by first turning valve handle counterclockwise. Then, turn hex nut

counterclockwise until valve handle and stem are free.

8. Wash inside of draw-off valve with a nylon brush.

9. Rinse kettle valve interior and reassemble valve.

NOTE: Leave draw-off valve open when kettle is not in use.

10. Remove swing drain and its strainer. Wash, rinse and replace.

Cooking Facts for Steam Jacketed Kettles:

A Steam Jacketed Kettle is a stainless steel kettle jacketed or encapsulated by a second outer kettle,
creating a space between the two kettles. Cooking is achieved by allowing steam to flow within this
space. The jacket or outer kettle usually covers 2/3 of the inner kettle, although some kettles are fully
jacketed

The steam flowing in the space between the kettles condenses on the cold inner kettle wall and releases
heat through the wall to the food in the kettle. The condensate drains to the bottom of the kettle and is
released through a steam trap without any loss or variation in steam pressure. The amount of steam
allowed to flow Into the Jacket controls the heat of the kettle. In use, the Steam Jacketed Kettle provides
consistent heat distribution and is energy efficient using steam only to maintain pressure, unlike top of
the range cooking in which energy (gas or electricity) is used during the entire cooking process.

Steam Jacketed Kettles can sauté, simmer, or boil a wide variety of products, such as soups, gravies,
sauces, pasta, stews, mixed casserole type dishes, vegetables, shellfish, cereals, hot beverages, and
puddings. A Steam Jacketed Kettle will not burn foods. However, foods that caramelize at relatively low
temperatures, such as eggs and milk based products, will coat and cook onto the sides of the kettle.
Care should be taken to use the smallest flow of steam, to lessen the possibility of scorching these
products. To achieve this, allow products to come up to desired temperature, stirring frequently, then
turn off steam flow and gradually turn on a small flow of steam - just enough to allow food to cook.

Steam Jacketed Kettles eliminate much range top cooking and greatly reduce the number of pots and
pans required. Because they are made of stainless steel, they are durable, non-porous and easy to clean.

 Estimate actual cooking capacity of Steam Jacketed Kettles at 3,4 of its volume, to allow stirring

without spillage.

 Plan an adequate drain arrangement. This is very important for ease of use and to minimize wet

floors. A grated gutter type drain located in front of the kettles is preferred as it eliminates the
hazards of tripping over a curb or stumbling into a recessed drain area.

 Locate a source of water (swivel faucet or flexible hose type) near the kettle to facilitate filling

and cleaning.

 Cover products whenever possible to save energy. Covered water boils 25 to 30% faster.
 Use the tangent draw off valve to drain off products from the kettle such as sauces and

puddings, or cooking liquids that are being discarded (as in the case of the water used to cook
pasta)