Service Manual - Market Forge Industries
Contents
1. x ss aw LEVEL CONTROL 10K onm iw 711 aw orsa LEVEL CONTROL 1M onm OPTIONAL f s sre IGNITION MODULE INTERMITTENTPLOT Jr x suem Remene OOOO y x suem usowsscxwswpr 2 l ma sex Tu su cowecrowcxwwer lt r 3 2 3 5 suem s swmnacrmmRowGug o o aje INIA gt INI a gt eja gt gt gt gt gt 55 gt gt 7 gt gt gt gt gt gt gt om 1 2 gt gt JUNE 12 2015 10 ST 5G MAIN ASSEMBLV ITEM PART NUMBER DESCRIPTION OOOO 15 Ti a rem wowowwsumwop Ti e ors cowecroessoxsaMPT Ti OOO O 0 y p cem sexe OOOO 49 sem muerwuesP 1 sew meeweR Ti p wem 8585 wem E 5 wem sew ss eraaia PROBE Low LEVELOUTORR 1 5 erasra prosevigHuevel Ti was Li Fuue coverassenaly Ti a ww SCREW 420012 mer Yroranvsinerse 62 RIGHT HAND SIDE RISER LEFT HAND SIDE RISER o FRONT RISER 97 62. 221 6221 REAR RISER a orem e wosecaw e sre 117 er sremr msowiecxwwpr 117 e srsm TRANSFORMER 5 s 7 sus memwosmreusrmmG Jr m waeRsumvcomecrnR 968196 TRANSFORMER 100vA 200 2407120v 20VUNTTS 1 Not Shown Select as Required gt gt JUNE 12 2015 11 ST 5G DOOR ASSEMBLV a ITEM PART NUMBER DESCRIPTION QTV 1 97 6227 DOOR FRAME 1 2 97 6231 DOOR HANDLE ASSEMBLV 1 97 6235 DOOR HANDLE DECAL 1 3 97 6232 LATCH ASSEMBLY 1 4 97 6261 BUSHING SPACER 4 5 97 6236 UPPER amp LOWER SPACER 1 ea 6 97 6230 DOOR PANEL 1 7 97 6228 DOOR GASKET 1 8 97 6229 GASKET PLATE 1 9 97 6233 GASKET PANEL SCREWS 8 10 97 6173 DOOR ASSEMBLV 1 JUNE 12 2015 12 ST 5G BURNER PROPANE AND NATURAL GAS ASSEMBLV PART NUMBER DESCRIPTION 1 NPN HEX SHELF TAPPING SCREW 8 32 x 1 4 4 2 97 6244 PILOT BURNER LIQUID PROPANE 1 97 6465 PILOT BURNER NATURAL GAS 1 3 97 6245 BURNER MOUNTING BRACKET 1 4 NPN MACHINE SCREW 10 32 x 3 8 2 5 NPN MACHINE SCREW 10 32 x 1 4 2 6 97 6237 SPARK ELECTRODE 1 7 97 6533 PILOT TUBE 1 8 98 6124 PIPE PLUG 1 8 MPT 1 9 97 6239 GAS MANIFOLD ASSY NATURAL GAS 1 97 6247 GAS MA
3. NG AND FIXING THE PROB LEM Timer Contacts 60 Minute Timer Defective timer contacts will result in failure of cooker compartment to operate When this occurs remove the control pan and proceed as follows 1 Turn off power to the cooker at external circuit break er 2 Disconnect all five wires from timer terminals 3 Connect an ohmmeter terminals 1 and 3 4 Rotate timer dial beyond the 0 minute point any setting to obtain a reading of zero ohms on the ohmmeter If zero ohm reading cannot be obtained timer contacts are defective and the timer must be replaced 5 Move ohmmeter leads to terminals 1 and 4 6 Rotate timer dial to 0 minute position an audible click indicates correct position If zero ohm reading cannot be obtained timer contacts are defective and the timer must be replaced 7 Remove ohmmeter and replace all five leads on timer terminals Timer Motor 60 Minute Timer A defective timer motor will cause continuous operation in the TIME mode with the timer dial failing to return to the 0 minute position Carefully check motor condition proceed as follows 1 Carefully check motor wire leads and tighten lose connections WARNING USE CARE WHILE WORKING WITH CONTROL PANEL TERMINALS CARRY 120 VOLTS 2 on power to the steamer 3 Set timer dial any setting beyond 0 minute If opera tion s correct the motor will turn the dial toward O minute If the motor fai
4. NIFOLD ASSY L P 1 10 NPN HEX CAP SCREW 1 4 20 x 1 2 2 11 97 6535 JET ORIFICE 64 L P 4 97 6498 JET ORIFICE 53 NATURAL GAS 4 12 97 6238 TWIN BURNERS NATURAL GAS 2 97 6246 TWIN BURNERS L P 2 13 NPN SHEET METAL SCREW 4 Not Shown Select as Required JUNE 12 2015 13 ST 5G GAS PLUMBING AND VALVE ASSEMBLV mir d 19 gear 0 9 PART NUMBER DESCRIPTION QTV 1 97 6249 BALL VALVE 3 4 1 2 NPN SCREW 10 32 x 1 2 2 3 97 6250 GAS SUPPLY PIPE ASSEMBLY 1 4 98 6112 REDUCING COUPLING 1 5 97 6251 90 STREET ELBOW 1 6 98 6109 CLOSE NIPPLE 1 2 1 7 98 6122 UNION ELBOW 1 2 1 8 97 5808 COMBINATION GAS CONTROL NATURAL 1 8 97 5809 COMBINATION GAS CONTROL PROPANE 1 9 97 6252 FLEX TUBE 1 2 x 18 1 Select as Required JUNE 12 2015 14 ST 5G
5. dy MARKET FORGE On p I N DU S T ST 5G GAS COUNTERTOP CONVECTION STEAMER PARTS AND SERVICE MANUAL EFFECTIVE JUNE 12 2015 Superseding All Previous Parts Lists The Company reserves the right to make substitution in the event that items specified are not available ERRORS Descriptive and or typographic errors are subject to correction MARKET FORGE INDUSTRIES 44 Lakeside Avenue Burlington Vermont 05401 USA Telephone 802 658 6600 Fax 802 860 3732 www mfii com P N 14 0287 Rev C TABLE OF CONTENTS GENERAL TROUBLESHOOTING Irc te res 3 TROUBLESHOOTING iadan a d u Eos 5 ELECTRICAL FAULT ISOLATION GUIDE III 6 WIRING DIAGRAMS ux eaae inea e m n M NU lp ip Ames 7 ILLUSTRATED PARTS LIST lt Pat liens Se 38255555555 500 9 DOOR ASSEMBLY ee bees 12 BURNER PROPANE AND NATURAL GAS 55 13 GAS PLUMBING AND VALVE ASSEMBLY 14 JUNE 12 2015 2 ST 5G GENERAL TROUBL PROBLEM PROBABLE CAUSE ESHOOTING GUIDE REMEDV 1 1 Cooking Indicator Light Fails to Light with Timer Set a Main power circuit breaker tripped Located external circuit breaker for incoming power and place in ON pos
6. er If the buzzer does not sound at the termination of the op erator selected timer setting timer dial returned to 0 min ute position the fault may be a defective buzzer Buzzer operation os verified using an AC volt meter at buzzer coil connections with input power on a selector switch and co inciding timer dial set at the 0 minute position If voltage is 120 volts the fault is in the buzzer which must be re placed If 120 volts is not present the fault is in the wiring control components selector switch or timer Wiring Using an ohmmeter wiring continuity between the con nections shown on the wiring diagram is readily verified This is best done in stages removing only those wires required for each continuity check As each lead is re placed it should be checked for evidence of corrosion and cleaned if necessary All leads must be tightly attached so as to provide a good electrical connection JUNE 12 2015 ST 5G TROUBLESHOOTING Door Gasket Replacement The cooking compartment door gaskets are made of sili cone type rubber material that is very durable but subject to wear during normal operation Should the gasket leak replace it as follows 1 Open the cooking compartment door 2 Remove the four screw on the outside of the door frame and remove the door panel assembly 3 Remove the six screw from the gasket plate in the door panel assembly 4 Remove the gasket plate and the door gasket from
7. ition b Doorinterlock switch contacts not closed Shut cooker door to close switch contacts Check alignment of door with switch c Door interlock switch faulty Replace switch d Indicator light burned out Replace light e Faulty timer contacts Replace timer f Faulty wiring Inspect condition of wire and tightness of all connections Correct as needed 2 Steam Fails to Enter Cooking Compartment with Cooking Indicator Light On a Faulty wiring Inspect condition of wire and tightness of all connections Correct as needed 3 Steam Enters Compartment Continuously Timer Dial Not Turning a Constant steam position Move knob to timing location b Faulty thermostatic switch Replace switch c Faulty timer motor Replace timer d Faulty wiring Inspect condition of wire and tightness of all connections Correct as needed 4 Steam Continues to Flow into Compartment and or Buzzer Fails to Sound at End of Timer Setting a Faulty timer contacts Replace timer b Faulty buzzer Replace buzzer c Faulty wiring Inspect condition of wire and tightness of all connections Correct as needed 5 Steam Flows Continuously from Boiler Drain Line with Cooker in Operation a Cold water not connected Turn on external shut off valve b Faulty cooling valve Replace cooling valve c Faulty wiring Inspect condition of wire and tightness of all connections Correct as needed 6 DoorLeaks a Damaged door gasket Check gasket for cuts and replace a
8. ls to operate it is defective and the entire timer must be replaced 4 Shutoff power to the cooker Door Interlock Switch Malfunction of the cooker door interlock switch prevents timer indicator light from turning on and steam solenoid from opening when the timer dial is set If steam does not enter the compartment and the cooking indicator light fails to turn on with the door latch securely engaged the fault may be in the door interlock switch Proceed as follows 1 Turn off power to the cooker 2 Disconnect wire to the door switch terminals 3 Connect an ohmmeter between the terminals of the switch 4 Actuate the switch by closing the cooking compart ment door If zero ohm reading cannot be obtained timer contacts are defective and the timer must be replaced 5 Remove the ohmmeter and replace the leads on switch terminals Indicator Lights If the cooker compartment functions correctly with the single exception that the indicator light fails to light during operation the fault is a defective indicator light A burned out or defective light is verified by using a AC volt meter at the leads with input power on the selector switch in correct position for that timer the timer set and the door latches closed If 120 volts is present the fault is in the indicator light and requires replacement If 120 volts is not present the fault is in the wiring control components selector switch timer or door switch Buzz
9. s a Constant steam position to turn b Timer motor c Wiring BUZZER fails to sound at the end of 60 MINUTE TIMER mode a 60 minute timer b Buzzer c Wiring Steam flows continuously from boiler drain line a Cooling valve needs replacing b Wiring JUNE 12 2015 ST 5G WIRING DIAGRAMS 56 220V MARKET FORGE ST ST 5G JUNE 12 2015 WIRING DIAGRAMS 56 0 120V MARKET FORGE 5 56 R O 220V MARKET FORGE ST ST 5G JUNE 12 2015 MAIN ASSEMBLV 2R2 5671 ST 5G JUNE 12 2015 MAIN ASSEMBLV ITEM PART NUMBER DESCRIPTION 3 osm 1 4 _ 2 CS 4 uerrmwosoERNDBACKERNEL 711 oreo p New Hexmu 0 Ta sex 717 smeg 2 sem moruen o 22717 a 97 6065 ors PERFORATED DOOR trouvan OPERATION NSTRUCTIONDECAL Jr uw FUSE 2A 250v aovuNT 11 re s srsm a srsws x see coweowewrwouwmNGSON m sem x rowers 3 oso muzm 26 sm y 3s
10. s needed b Clogged compartment drain or plumbing Remove screen and clean drain line or plumbing 7 Water Flows into Cooking Compartment a Level probe short circuited Check and correct b Scale build up on probe Clean all probes c Water fill solenoid valve Plugged defective clean or replace 8 Water Accumulates in Compartment a Plugged compartment drain Remove screen and clean drain line 9 Water Flows into Drain During Shut Down a Cooling valve does not close Check valve for foreign material or damage JUNE 12 2015 ST 5G GENERAL TROUBLESHOOTING GUIDE PROBLEM PROBABLE CAUSE 10 Water not Being Supplied to Generator REMEDV a Water supply off Check incoming water valve is on Supply water pressure too low Call supply agency Defective water solenoid valve Replace or clean Level probe shorted Check and correct Defective water level control Replace f Drain valve is open Check valve clean or replace IMPORTANT NOTE These problems are an indication of severe water conditions which should be corrected immediatelv to avoid damage to the components and performance of the steamer Call vour Service for Assistance ADJUSTMENTS All units are adjusted at the factory in case of operation problems at initial installation check type of gas supply and manifold pressure and compare it with information on the rating pla
11. te 11 Burners Do Not Come On a Gas supply is off Locate supply line and turn on Power switch is off Located switch in cabinet and turn on Probe not sensing water level Clean probes check wiring Ignitor not functioning Check ignition module relay Combination gas valve not opening Check that control knob is in the ON position check that 120 volts is at the gas valve 12 Burners Produce Carbon Deposits a Incorrect orifice size Check size and correct b Incorrect gas supply Check size and correct c Incorrect gas pressure Check gas pressure at manifold Correct if necessary 13 Flash Back a Burning inside mixer tube Reduce primary air Incomplete combustion Increase burner input Increase primary air b c Sooting of burner d Miss ocated ignitor Adjust ignitor IMPORTANT NOTICE AT LEAST TWICE A YEAR HAVE AN AUTHORIZED SERVICE PERSON CLEAN AND ADJUST THE UNIT FOR MAXIMUM PERFORMANCE ADJUSTMENTS AND SERVICE WORK MAY BE PERFORMED ONLY BY A QUALIFIED TECHNICIAN WHO IS EX PERIENCED IN AND KNOWLEDGEABLE WITH THE OPERATION OF COMMERCIAL GAS COOKING EQUIPMENT HOWEVER TO ASSURE YOUR CONFIDENCE CONTACT YOUR AUTHORIZED SERVICE AGENCY FOR RELIABLE SERVICE DEPENDABLE ADVICE OR OTHER ASSISTANCE AND FOR GENUINE FACTORY PARTS JUNE 12 2015 4 ST 5G TROUBLESHOOTING FINDING UNDERSTANDI
12. the door panel 5 Install the new door gasket to the door panel Replace the gasket plate and six screws 6 Reassembly the door panel assembly in the door frame using the four screws 7 Gasket replacement is now complete Door may be difficult to close until the gasket has com pressed to conform to the door opening Leaving door closed overnight will compress gasket Exterior Panel Removal AN WARNING TO PREVENT HAZARD IN SERVICING THE COOKER BE CERTAIN THAT THE STEAM SUPPLY BOILER IS SHUT DOWN THE COLD WATER SHUT OFF VALVE IS CLOSED AND THE ELECTRICAL DISCONNECT CIRCUIT BREAKER FOR THE COOKER BOILER UNIT IF OFF BEFORE REMOVING SIDE PANELS Access to all internal plumbing and electrical assemblies is from the right side The right side panel is removed by removing the bottom screws and pushing up on the panel until the lower lip disengages from the frame Gas control is located on the right side behind the bottom panel Re move the four screws ELECTRICAL FAULT ISOLATION GUIDE Will not operate in either CONSTANT STEAM or 60 MINUTE TIMER a Incoming power itions b Timer Doorinterlock switch d Wiring Operating in CONSTANT STEAM position but not in 60 MINUTE TIM a 60 minute timer ER ition i b Wiring Operates in 60 MINUTE TIMER position but not in CONSTANT a Timer STEAM ition b Wiring With indicator light on and steam solenoid valve open timer dial fail
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