Market Forge R-RCM-36 Service Manual

0

OWNER’S MANUAL

CheeseMelter/Broiler

Salamander/Broiler

MODELS:

□ R-RCM-24
□ R-RCM-36
□ R-RCM-48
□ R-RCM-60

MODELS:

□ R-RSB-24
□ R-RSB-36
□ R-RSB-48

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.

FOR YOUR SAFETY:

DO NOT STORE OR USE GASOLINE OR OTHER

FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY

OF THIS OR ANY OTHER APPLIANCE.

Form Number: S-6103 10/12
Printed in USA 35 Garvey Street, Everett, MA 02149

Telephone [phone], Fax [phone]

[e-mail], www.mfii.com

CAUTION:

INSTRICTIONS TO BE FOLLOWED IN THE EVENT

THE USER SMELLS GAS SHALL BE POSTED IN A

PROMINENT LOCATION. THIS INFORMATION

SHALL BE OBTAINED BY CONSULTING THE LOCAL

GAS SUPPLIER.

IMPORTANT:

MUST ORDER REINFORCEMENT CHANNELS IF

MOUNTING TO OVEN OR RANGE.

INSTALLATION, OPERATION, MAINTENANCE, SERIVE & PARTS LIST

1

Table of Contents

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

Important Information: ............................................................................................................... 2

Shipping Damage Claim Procedure: ............................................................................................ 2

Visible loss or damage: ........................................................................................................... 2

File claim for damages immediately: ...................................................................................... 2

Concealed loss or damage: ..................................................................................................... 2

Service: ........................................................................................................................................ 2

Air Supply and Ventilation:.......................................................................................................... 3

Disclaimer: ................................................................................................................................... 3

INSTALLATION ................................................................................................................................ 4

READ BEFORE INSTALLING .......................................................................................................... 4

Clearance: ............................................................................................................................... 4

Rating Plate: ............................................................................................................................ 4

Gas Connection: ...................................................................................................................... 4

Manual Shut-Off Valve: ........................................................................................................... 4

Pressure Regulator: ................................................................................................................. 4

Dimensions:............................................................................................................................. 5

Connections: ........................................................................................................................... 5

Initial Pilot Lighting: ................................................................................................................ 5

Specifications: ............................................................................................................................. 6

CheeseMelter .......................................................................................................................... 6

Salamander ............................................................................................................................. 6

Standard Features: ...................................................................................................................... 6

Broiler Grid: ............................................................................................................................. 6

Rack Assembly: ....................................................................................................................... 6

Adjustable Rack: ...................................................................................................................... 6

ASSEMBLY ....................................................................................................................................... 7

RANGE MOUNTING: .................................................................................................................... 7

COUNTER or WALL MOUNTING: ................................................................................................. 7

OPERATION ..................................................................................................................................... 8

LIGHTING & SHUTDOWN: ........................................................................................................... 8

MAINTENANCE ............................................................................................................................... 9

Daily Cleaning: ......................................................................................................................... 9

Periodic Cleaning: ................................................................................................................... 9

Cleaning Stainless Steel: ......................................................................................................... 9

ILLUSTRATED PARTS ..................................................................................................................... 10

CheeseMelter Exploded View ............................................................................................... 10

CheeseMelter Parts List ........................................................................................................ 11

Salamander Exploded Views ................................................................................................. 13

Salamander Parts List ............................................................................................................ 14

2

INTRODUCTION

Installation of the equipment should be performed by qualified, certified and authorized personal who
are familiar and experienced with local installation codes.

Before installation please red instructions completely and carefully.

Do not remove permanently affixed labels, warnings or plates from unit.

Important Information:

Please observe all local and national codes and ordinances. Installation must conform with local codes,
or in the absence of local codes, the National Fuel Gas Code ANSI Z223.1. In Canada, installation must
conform to installation codes for gas burning appliances and equipment standard CAN/CGA-B149.1 or
the Propane installation code CAN/CGA-B149.2 as applicable.

A manual gas shut off valve must be installed in the gas supply line ahead of the unit and gas pressure
regulator for safety and ease in servicing.
The gas pressure regulator supplied must be installed on the unit prior to connecting the equipment to
the gas line. Failure to install a regulator could be potentially hazardous and will void warranty.

The unit and its individual shut off valve must be disconnected from the gas supply piping system during
any pressure testing for that system at test pressures in excess of 1/2 PSI.

The unit must be isolated from gas supply piping system, by closing its individual manual shut off valve
during and pressure testing of the gas supply piping system at test pressure equal to or less than 1/2 PSI.

Shipping Damage Claim Procedure:

The equipment is crafted and inspected carefully by skilled personnel before leaving the factory. The
transportation company assumes full responsibility for safe delivery upon acceptance of this equipment.
If shipment arrives damaged:

Visible loss or damage:

Note the damage or loss on freight bill or express delivery and signed by the person making the delivery.

File claim for damages immediately:

Regardless of the extent of damages.

Concealed loss or damage:

If damage is noticed after unpacking, notify the transportation company immediately and file a
"Concealed Damage" claim with them. This should be done within fifteen (15) days from the date

delivered. Retain container for inspection.

Service:

Installation & Service of the equipment should be performed by qualified, certified, licensed and/or
authorized personnel who are familiar with and experienced in state/local installation codes.

Operation of the equipment should be performed by qualified and authorized personnel who have read
this manual and are familiar with the functions of the equipment.

3

Air Supply and Ventilation:

The area in front of, around and above the appliance must be kept clear to avoid any obstruction of the
flow of combustion and ventilation air. Adequate clearance must be maintained at all times in front and
at the sides of the appliances for servicing and proper operation.

Means must be provided for any commercial, heavy-duty cooking appliance to exhaust combustion
waste products to the outside of the building. Usual practice is to place the unit under an exhaust hood.
Filters and drip troughs should be part of any industrial hood. Consult local codes before constructing
and installing a hood.

Strong exhaust fans in this hood or in the overall air conditioning system can produce a slight vacuum in
the room and/or cause air drafts, either of which can interfere with pilot or burner performance and can
also be hard to diagnose. Air movement should be checked during installation; if pilot or burner outage
problems persist, make-up air openings or baffles may have to be provided in the room.

Disclaimer:

All MARKET FORGE INDUSTRIES, INC. appliances are adjusted and tested before leaving the factory,
effectively matching them to sea level conditions. Adjustments and calibrations to assure proper
operation may be necessary on installation to meet local conditions; low gas characteristics, to correct
possible problems caused by rough handling or vibration during shipment, and are to be performed only
by qualified service personnel. These adjustments are the responsibility of the customer and/or dealer
and are not covered by our warranty.

4

INSTALLATION

UNIT MUST BE CONNECTED ONLY TO THE TYPE OF GAS IDENTIFIED ON THE RATING PLATE!

READ BEFORE INSTALLING

Clearance:

When installing against combustible surfaces; rear and sides - 4” (102mm) clearance is required. When
installing ovens against non-combustible surfaces (rear or side walls) 0” clearance is required.

The area around the appliance must be kept free and clear of combustibles such as solvents, cleaning
liquid, broom, rags, etc. Proper clearances must be provided at the front of the appliance for servicing
and proper operation.

Rating Plate:

The rating plate is located in front of the range below the oven section. Information on this plate
includes the model, and serial number, BTU / hour input of the burners, operating gas pressure in inches
WC, and whether the appliance is orificed for Natural or Propane gas. Pilot lighting instructions are also
located in the same area.

Gas Connection:

The gas supply (service) line must be the same size or greater than the inlet line of appliance. Oven uses
a 3/4” NPT inlet. Sealant on all pipe joints must be resistive to LP gas. Specify type of gas and altitude if
over 2,000 feet when ordering.

Manual Shut-Off Valve:

This installer-supplied valve must be installed in the gas service line ahead of the appliance and
regulator in the gas stream and in a position accessible in the event of an emergency.

Pressure Regulator:

Gas pressure regulator provided with the equipment must be installed when the appliance is connected
to gas supply.

All commercial cooking equipment must have a pressure regulator on the incoming service line for safe
and efficient operation, since service pressure may fluctuate with local demand. The pressure regulator
comes with the oven. Failure to install the pressure regulator will void the equipment warranty!

The regulators supplied with MARKET FORGE INDUSTRIES, INC. Ovens, have 3/4” inlet /outlet openings
and are adjusted at the factory for 5” WC (Natural gas) or 10” WC (Propane gas) depending on

customer’s ordering instructions.

Prior to connecting the regulator, check the incoming line pressure, as these regulators can only
withstand a maximum pressure of ½ PSI (14”WC). If the line pressure is beyond this limit, a step-down
regulator will be required. The arrow shown on the bottom of the regulator body shows gas flow
direction; it should point downstream to the appliance. The red air vent cap on the top regulator is part
of the regulator and should not be removed.

5

Any adjustments to regulators must be made only by qualified service personnel with the proper

Before lighting, check all joints in the gas supply line for leaks.

DO NOT USE AN OPEN FLAME TO CHECK FOR LEAKS!

Putting an open flame beside a new gas connection is extremely dangerous.

DO NOT USE APPLIANCE DURING PROLONGED POWER FAILURE AS THE VENT HOOD MAY NOT BE IN
OPERATION RESULTING IN INADEQUATE VENTING!

CAUTION: When lighting pilots and checking for leaks, do not stand with your face close to the
combustion chamber.

Check all gas connections for leaks with a soapy water solution before lighting any pilots.

equipment.

Dimensions:

Connections:

Please check installer-supplied intake pipes visually and /or blow them out with compressed air to clear
any dirt particles, threading chips, or other foreign matter before installing a service line. When gas
pressure is applied these particles can clog orifices. All connections must be sealed with a joint
compound suitable for LP gas, and all connections must be tested with a soapy water solution before
lighting any pilots!

Initial Pilot Lighting:

6

Specifications:

MODEL

WIDTH

NO. OF BURNERS

TOTAL BTU

SHIP WEIGHT

R-RCM-24

24” (610mm)

11

20,000

105 lbs.

R-RCM-36

36” (914mm)

12

35,000

165 lbs.

R-RCM-48

48” (1219mm)

21

40,000

210 lbs.

R-RCM-60

60” (1524mm)

2

1&2

55,000

275 lbs.

MODEL

WIDTH

NO. OF BURNERS

TOTAL BTU

SHIP WEIGHT

R-RSB-24

24” (610mm)

11

17,500

160 lbs.

R-RSB-36

36” (914mm)

21

35,000

201 lbs.

R-RSB-48

48” (1219mm)

22

40,000

252 lbs.

CheeseMelter

Salamander

1

Infra-red burner rated at 20,000 BTU/hr each.

2

Infra-red burner rated at 35,000 BTU/hr each.

Standard Features:

Standard features for both units include, high efficient infra-red burners provide uniform heating,
removable crumb tray, adjustable infra-red burners, standing pilots for instant ignition and wall
mounting brackets.

The CheeseMelter/Broiler also comes with heavy duty chrome racks, that easily move in two positions,
and a full drip pan for easy clean up.

The Salamander/Broiler is equipped with spring balanced broiler grid that moves up and down with
positive locking in three positions, and roll-out carriage for easy loading and unloading.

Broiler Grid:

One piece broiler grid chrome plated and made of heavy duty bar stock.

Rack Assembly:

Rolls out adequately for loading, unloading and removes for cleaning.

Adjustable Rack:

Only available on salamander models. Broiler rack has spring balance and adjustable tension assembly
(rises and lowers with positive multi-position locking).

7

ASSEMBLY

RANGE MOUNTING:

Available to mount on any Market Forge Range using optional heavy duty reinforcement channels (p/n
00-0000) that fit existing back guard.

COUNTER or WALL MOUNTING:

Mount on any counter surface with the optional 4” legs. Also, mount on any wall type with the optional
wall mounting kit (p/n 00-0000).

NOTE: If a Salamander /Broiler or CheeseMelter/Broiler is to be mounted on range, it should be
installed by an authorized service tech. Special care must be taken to ensure that the gas supply piping
and/or gas pressure regulator is not exposed to exhaust gases, or elevated temperatures.

NOTE: Width of the unit cannot exceed width of the range it is mounted on.

8

OPERATION

Before lighting any pilots, make sure that burner valves and thermostats are turned “off”.

LIGHTING & SHUTDOWN:

1. Turn all valves to OFF position.

2. Wait 5 minutes.

3. Turn pilot valve(s) adjusting screw counterclockwise, then light standing pilot and adjust
flame 1/4” high.

4. Turn ON gas valve(s) to light main burner.

5. For complete shutdown, shut OFF gas valve(s) and turn pilot valve(s) adjusting screws
clockwise

9

MAINTENANCE

If the appliance is on casters and is connected to the supply piping by means of a connector for movable
appliances, there is a restraining device at the rear of the unit. If disconnection of the restraint is
necessary, reconnect the restraint after the appliance has been returned to its originally installed
position.

CAUTION: Never use Ammonia in an Oven that is warmer than room temperature and always have
direct ventilation.

Daily Cleaning:

1. Remove large pieces of food residues and carefully scrape spill lovers from drip tray below the

cooking surface.

2. Wash all exterior and interior surfaces with hot soapy water solution. Do not use any abrasives

on any other portion of the stainless steel surface.

3. Cast iron grates should be scraped frequently with a wire brush and periodically soaked in soapy

hot water to remove grease particles. Never expose the grates to excessive heat for the purpose
of burning excess grease. This practice could shorten the useful life of the grates.

4. Infra-red burners available on cheesmelters and Salamanders are self-cleaning. The use of any

solvents or wire brushes nay damage tiles.

5. For charbroilers use lava rock. This pumice rock is highly porous and relatively self-cleaning. The

lava rock should be turned over about every week depending upon the amount of cooking and
type of food prepared.

High heat will effectively clean and burn off grease. A loosely placed lower layer of rock will
serve as an effective base. About one half layer of rock should be added to compensate for hot
pots. Over filling the char broiler will obstruct proper air flow creating poor combustion and
uneven heating pattern and will ultimately shorten the useful life of cast iron bottom grates and
burners. As the lava rock disintegrates over a period of time it needs replacement.

Periodic Cleaning:

Remove burner and clean with warm water and wire brush. Make sure the ports are not clogged. Check
valves and lubricate, if necessary. Consult your service agency or local Gas Company.

Cleaning Stainless Steel:

All stainless steel body parts should be wiped regularly with hot soapy water during the day and with a
liquid cleaner designed for this material at the end of each day.

DO NOT USE steel wool, abrasive cloths, cleaners or powders to clean stainless surfaces! If it is
necessary to scrape stainless steel to remove encrusted materials, soak in hot water to loosen the
material; then use a wood or nylon scraper.

DO NOT USE a metal knife, spatula, or any other metal tool to scrape stainless steel. Scratches are
almost impossible to remove.

10

CheeseMelter Exploded View

ILLUSTRATED PARTS

11

CheeseMelter Parts List

ITEM

NO.

PART

NO.

DESCRIPTION

1

93-5343

24" Top cover

93-5344

36" Top cover

93-5345

48" Top cover

93-5346

60" Top cover

93-5347

72" Top cover

2

93-5348

Infra-red burner – Small B-20 (RCM-24”, 48”, 60”)

93-5349

Infra-red burner – Big B-35 (RCM-36”, 60”, 72”)

3

93-5350

Pilot burner w/bell orifice (natural gas)

93-5351

Pilot burner w/bell orifice (propane gas)

93-5352

#18 Pilot bell orifice only (natural gas)

93-5353

#10 Pilot bell orifice only (propane gas)

4

93-5354

Gas pressure regulator (natural gas)

93-5355

Gas pressure regulator (propane Gas)

5

93-5356

Orifice spud #46 (brass) natural gas, 20,000BTU*

93-53

57

Orifice hood #46 (alternate) natural gas 20,000BTU*

93-5358

Orifice spud #55 (brass) natural gas, 20,000BTU*

93-53

59

Orifice hood #55 (alternate) propane, 20,000BTU*

93-5360

Orifice spud #39 (brass) natural gas, 30,000BTU*

93-5361

Orifice hood # 39 (alternate) natural gas, 30,000BTU*

93-5362

Orifice spud #52 (brass) propane, 30,000BTU*

93-5363

Orifice hood #52 (alternate) propane, 30,000BTU*

93-5364

90º Orifice elbow, rectangular (brass)

6

93-5365

3/8” CC x 3/8-27 Orifice elbow (brass)

7

93-5366

Manifold pipe assembly (right side gas inlet)

93-5367

Manifold pipe assembly (left side complimentary assy)

8

93-5368

1/8" NPT x 3/16" CC Adjustable single pilot valve (brass)

9

93-5369

3/8-27 x 3/8" CC Adapter

10

93-5370

Gas valve (brass) w/out orifice

11

93-5371

Blue knob – flat side down

12

93-5372

24” Crumb tray

93-5373

36” Crumb tray

93-5374

48” Crumb tray

93-5375

60” Crumb tray

93-5376

72” Crumb tray

13

93-5377

24" Chrome rack

93-5378

36" Chrome rack

93-5379

48" Chrome rack

93-5380

60" Chrome rack

93-5381

72" Chrome rack

14

93-5382

24” Wall mount kit

93-5383

36” Wall mount kit

93-5384

48” Wall mount kit

93-5385

60” Wall mount kit

12

ITEM

NO.

PART

NO.

DESCRIPTION

14

93-5386

72” Wall mount kit

15

93-5387

Reinforcement Channels (range mount kit, specify range model# )

* Verify which construction is applicable for your burner type.

13

Salamander Exploded Views

14

Salamander Parts List

ITEM

NO.

PART

NO.

DESCRIPTION

1

93-5388

24” Top cover

93-5389

36” Top cover

93-5390

48” Top cover

2

93-5391

Infra-red burner - Small B-15(RSB-36 – 2 burner)

93-5392

Infra-red burner – Big B-20 (RSB-24 – 1 burner)

93-5393

Pilot burner with bell orifice (natural gas)

3

93-5394

Pilot burner with bell orifice (propane Gas)

93-5395

#18 Pilot bell orifice only (natural gas)

93-5396

#10 Pilot bell orifice only (propane Gas)

4

93-5397

Gas pressure regulator (natural gas)

93-5398

Gas pressure regulator (propane Gas)

5

93-5399

Orifice spud #46 (brass), natural gas (for 24”), 20,000BTU*

93-5400

Orifice hood #46 (alternate), natural gas (for 24”), 20,000BTU*

93-5401

Orifice spud #55 (brass), propane (for 24”), 20,000BTU*

93-5402

Orifice hood #55 (alternate), propane (for 24”), 20,000BTU*

93-5403

Orifice spud #48 (brass), natural gas (for 36“), 18,000BTU

93-5404

Orifice hood #48 (alternate) natural gas (for 36”) 18,000BTU

93-5405

Orifice spud # 56 (brass), propane (for 36”) 18,000BTU

93-5406

Orifice hood #56 (alternate), propane(for 36“), 18,000BTU

6

93-5407

3/8” CC x 3/8-27 Orifice elbow (brass)

93-5408

90o Orifice elbow (rectangular) (brass)

7

93-5409

Manifold pipe assembly (right side gas inlet)

93-5410

Manifold pipe assembly (left side assembly)

8

93-5411

1/8" NPT x 3/16" CC Adjustable single pilot valve (brass)

9

93-5412

3/8-27 x 3/8" CC Adapter (gas valve)

10

93-5413

Gas valve (brass) w/out orifice

11

93-5414

Blue knob – flat side down

93-5415

24" Cradle frame assembly

12

93-5416

36" Cradle frame assembly

93-5417

48” Cradle frame assembly

13

93-5418

Latch bracket

14

93-5419

24” Crumb tray assy.

93-5420

36” Crumb tray assy.

93-5421

48” Crumb tray assy.

15

93-5422

24" Rack assembly with pull out handle

93-5423

36" Rack assembly with pull out handle

93-5424

48” Rack assembly with pull out handle

93-5425

24” Drip pan

16

93-5426

36” Drip pan

93-5427

48” Drip pan

93-5428

24” Chrome rack

15

ITEM

NO.

PART

NO.

DESCRIPTION

17

93-5429

36” Chrome rack

93-5430

48” Chrome rack

93-5431

24” Front panel

18

93-5432

36” Front panel

93-5433

48” Front panel

93-5434

24” Wall mount kit

19

93-5435

36” Wall mount kit

93-5436

48” Wall mount kit

20

93-5437

Reinforcement Channels (range mount kit, specify range model# )

* Verify which construction is applicable for your burner type.