Market Forge Industries 3500 User's Manual
Contents
1. a 5 9 5 9 CONNECTOR WHT PILOT LIGHT 61 REED_ SWITCH UPPER 55 56 si LTI GRN 27 WHT 42 57 2 12 gt 28 COLD WATER CONDENSER RELAY R1 BLK 29 W gt 1 Ja COLD WATER CONDENSER 5 9 V2 BLK REED SWITCH BUZZER 52 81 UPPER 5 one RUN d ON 34 THERMOSTAT THERMOSTAT gt 2 2 SWITCH SWITCH 53 54 TIMER 4 gt 9 9 EL TIANG 60 MIN TIMER 479 TMRI UPPER 30 STEAM 123 SOL VALVE LOT LIGHT LOWER GRN 13 AONE 39 7 47 9 TBe BLK 5 49 BLK 48 BUZZER WHT gt 6 6 gt 82 LOWER TIMER 16 DONE RUN 12 64 gt 27 7 10 gt 60 MIN TIMER TO 120 240V TO 120 240v TMR2 SUPPLY BOX SUPPLY BOX LOWER N 21 BOILER CONTROL B AUTOMATIC BOILERS Jl O TO FRONT FRAME GRD NOTES 1 ALL WIRES 18 AWG AND YELLOW EXCEPT WHERE INDICATED OTHERWISE 2 FOR WIRE LEAD SCHEDULE REFER TO DRAWING 91 6472 0338 ih 1 9 59 AWLSOWY3HL 1109 WV3LS YISNJONOI 0102 z7 aazzng 1109 to L lt 1109 WV3LS YISNJONOI ga 0102 YOLOW 0334 1109 ta dul CoD dW Fig 3 Wiring and Schem 14 atic Diagram 0052 62 TROU2. naen aaa 13 ELECTRICAL FAULT ISOLATION GUIDE 13 WIRING AND SCHEMATIC DIAGRAM 14 TIMER MO TOR a baana ra ab aaa an ajag aan 15 DOOR INTERLOCK SWITCH 15 STEAM SOLENOID VALVES 2 15 INDICATOR LIGHTS 15 COOKING COMPARTMENT THERMOSTATIC SWITGH ai 15 BUZZER 16 COLD WATER CONDENSER CIRCUIT 16 MAINTENANCE GENERAL 16 PREVENTIVE MAINTENANCE 16 COOKING COMPARTMENT CLEANING 17 REPAIR AND REPLACEMENT 17 DOOR LATCH TENSION ADJUSTMENT 17 ILLUSTRATED PARTS LIST GENERAL coca 17 ORDERING INFORMATION 17 CABINET ASSEMBLY 18 DOOR ASSEMBLY 20 CONTROL PANEL ASSEMBLY 21 CONDENSER ASSEMBLY 22 COMPLETE CONDENSER ASSEMBLY 23 INTRODUCTION This service and parts manual contains general infor mation installation operation principles of operation trouble shooting and maintenance information for the Market Forge 3500 Pressureless Steam Cookers Also included is a parts list in which each replaceable part is identified and shown in an accompanying ex ploded view The 3500 is a pressureless steam cooker con
3. 3 REVERSING THE DOORS 3 OPERATION OPERATING CONTROLS AND INDICATORS 3 OPERATING PROCEDURES 3 STEAM SOURCE OPERATING 4 PREHEATING aa b na na aaa ag 4 COOKING baga ta Tag baana 4 SHUT DOWN PROCEDURE 4 CLEANING 4 DRAINAGE anana Sen Ka saning 4 COOKING DRAINAGE 4 DRIP SPILL TROUGH DRAINAGE 4 CONTROLS AND INDICATORS 5 FACTS ON PARADE 6 TIMER SETTINGS 7 PRINCIPLES OF OPERATION GENERAL a 9 PLUMBING CIRCUITS 9 STEAM INLET LINE n 10 STEAM EXHAUST AND DRAIN LINES 10 STEAM EXHAUST CONDENSING SYSTEM 10 ELECTRICAL CIRCUITS ecer 10 CONTROL CIRCUIT COMPONENTS 10 PICTORIAL DIAGRAM OF STEAM AND CIRCUITS orure ea aT 11 INDICATOR LIGHTS 11 BUZZER ic ranap ag anga Het huni A a A gg RA aa 11 DOOR INTERLOCK SWITCH 11 THERMOSTATIC SWITCH 11 TROUBLE SHOOTING GENERAL 12 GENERAL TROUBLE SHOOTING GUIDE 12 INCOMING POWER 13 ELECTRIC INSPECTION 13 60 MINUTE TIMER 13 TIMER CGONTAG TS
4. 65mm TIMER SETTINGS IN MINUTES 20 30 APPROX NO COOKED SERVINGS PER PAN 15 20 2 oz Protein 55 g 25 30 2 oz Protein 55 g 20 25 2 oz Protein 55 g NUMBER OF PANS 45 50 50 60 35 40 2 oz 55 9 20 25 2 oz Protein 55 g 20 25 2 oz Protein 55 9 50 60 2 oz Protein 55 9 18 22 20 25 Pork Chops 4 02 6 Ibs 2 1 2 1 3 25 30 24 Loin Bone 115 9 2 7 kg 65mm 2 02 Protein 55 9 Sausage 6 Ibs 2 1 2 1 3 18 21 1 1 2 oz 45 g 2 7 kg 65mm 18 20 2 02 55 9 Turkey 20 22 Ibs 2 1 2 1 2 2 1 2 hrs 50 60 On Carcass 9 10 kg 65mm 2 oz Protein 55 g Turkey 10 12 Ibs 2 1 2 1 3 1 1 1 4 hrs 55 65 Off Carcass 4 5 5 kg 65mm 2 02 Protein 55 g Raw weight for Meatballs and Meatloaf includes hamburg and extenders and yields 2 oz 55 g protein plus extenders or 3 oz 85 g total portion PRINCIPLES OF OPERATION GENERAL The 3500 Pressureless Steam Cooker consists of two identical cooking compartments one above the other in a single cabinet assembly Each compartment is fitted with independent electrically controlled steam circuits and spring loaded self sealing doors with slam action latches Compartments can be used sep arately or simultaneously for either constant steam or 60 minute timing The principles of operation in this section include an explanation of steam steam con densing and electrical circuits and their functioning PLUMBING C
5. ELECTRICAL CIRCUITS The electrical circuits of the cooker control the power to activate timer motors and energize solenoid oper ated valves and circuits which in turn control applica tion of steam to the cooking compartment and con densation of steam from the exhaust line The cooker operates 120V 2 60Hz electrical service connected to all circuits from the circuits of the steam boiler or direct connected steam controls contained within the cabinet on which the cooker is mounted Power is supplied to the control circuit at all times when the shut off device for the unit Supplied by the user is in the ON position CONTROL CIRCUIT COMPONENTS A brief de scription of the electrical circuit elements follows 60 MINUTE TIMER CONSTANT STEAM The timer contains a 120 volt AC synchronous mo tor that drives a timing dial through a gear reduction and clutch mechanism The timer dial is manually set for any interval of operation from 0 to 60 minutes or constant steam as read on the calibrated dial face The manual rotation of the dial moves the common element 1 of the timer switch from the neutral OFF position to contact 3 which connects with the steam inlet solenoid valve operating circuit The cooker is placed into automatic operation with the setting of the timer dial Its timing cycle however is automatically delayed by a thermostatic switch which assures operating temperature is achieved be fore the timer mot
6. and direct connected steam are shown in separate installation instructions for each WATER CONNECTIONS Before connecting water to this unit have water sup ply analyzed to make sure that hardness is no grater than 2 0 grains per gallon and pH level is within the range of 7 0 8 5 Water that fails to meet these stan dards should be treated by the installation of a water conditioner Equipment failure caused by inadequate water qual ity is not covered under warranty CAUTION PVC or CPVC are not acceptable materials for drains INSTALLATION CHECK OUT Check out procedures for the cooker mounted on steam boilers of electric gas and steam coil utility or direct connected steam are given in separate installa tion instructions for each If the cooker fails to perform as described consult the Trouble Shooting Guide for corrective action If difficulty arises with the boiler ref erence the separate service and parts manual for that equipment Before making this check out the operator must be thoroughly familiar with the operating procedures on page 3 and with the function of each control described in Table 1 on page 5 Reference Figure 1 also on page 5 for identification of controls required in the fol lowing procedures INITIAL CONTROL SETTINGS Before beginning the start up procedures for the cooker the instruction plate and service manual for the steam boiler must be consulted and all start up procedures completed to
7. parts are ordered ILLUSTRATED PARTS LIST N NG NAN ji f mah N INA NIA 2 ME d 27 AN TUT NANGGUNG NA NING AR NAN f y 32 NG a ILLUSTRATED PARTS LIST Fig 4 Cabinet Assembly ITEM PART DESCRIPTION QTY NO 7 2 1 1 14 1 91 763 STIFFENER BACK 98 350 PANEL BACK 91 761 PANEL TOP I 91 769 BRACKET REED SWITCH 2 2 22 2 24 2 2 2 2 2 4 91 570 RACK WIRE 91 649 DOOR ASSY 2 91 763 BRACKET LINER TIE 91 7684 STRAINER 2 91 769 BAFFLE RACK SLIDE 6 3 5 0 1 3 5 6 7 8 29 0 08 460 COMPRESSION SPRING 1 3 5 9 3 0 8 7 8 6 3 7 8 9 3 9 0 8 9 6 7 0 3 0 5 6 8 0 3 3 3 3 3 3 3 19 ILLUSTRATED PARTS LIST Fig 5 Door Assembly ITEM PART NO DESCRIPTION lt 91 5729 OUTER DOOR 91 5766 INNER DOOR 1 3 91 5731 GASKET RETAINING PLATE 5 O1 DOOR GASKET 5 91 5745 _ DOOR HANDLE 6 09 1608 _ STRIKER O7 7 08 5027 MAGNET 8 91 5901 MAGNET BRACKET o 08 4600 COMPRESSION SPRING 20 ILLUSTRATED PARTS LIST Fig 6 Control Panel Assembly ITEM PART NO DESCRIPTION QTY 5 50 2 os 3507_ ARTWORK GONTROLPANE
8. 1 2 a 2 s oreari BRACKET TERMINAL STRI 2 mors z 0885 OO O oo To e 10 6062 O O gt 21 ILLUSTRATED PARTS LIST gt WATER FLOW DIRECTION gt Fig 7 Condenser Assembly ITEM PART NO DESCRIPTION QTY 91 7640 CONDENSER BRACKET 08 4821 CONDENSER SOLENOID 08 4864 BARB 90 1 8 IPS 08 5009 TEE 1 8 IPS 1 4 ID HOSE 22 ILLUSTRATED PARTS LIST Fig 8 Complete Condenser Assembly ITEM PART NO DESCRIPTION QTY 86538 se 2 08 7970 NEOPRENE ____________________ a 5__ 102539 BUSHING 6 os5438 TEE 08207 ___________ 8 __ _167208 BRAIDED STAINLESS 5 5 2 1 os4s64 HOSE BARB o Jo o 08 1206 O o Jo een NG 42 08 4860 HOSE COUPLER v6 PSx14D 2 15 08 4821 CONDENSER 16 91 7640 CONDENSER BRACKET TT 23 D Rh I N oO
9. 3500 OWNER S MANUAL WARNING installation adjustment alteration service or maintenance can cause property damage injury or death Read the installa tion operation and maintenance instructions thoroughly before installing or servicing this equipment FOR YOUR SAFETY Do not store or use gasoline or other flam mable vapors and liquids in the vicinity of this or any other appliance Post in a prominent location instructions to be followed in the event the user smells gas This information shall be obtained by con sulting the local gas supplier MODEL 3500 INSTALLATION OPERATION MAINTENANCE SERVICE AND PARTS MANUAL Fi MARKET FORGE An Employee Owned Company 35 Garvey Street Everett MA 02149 Tel 617 387 4100 Fax 617 387 4456 Toll Free 866 698 3188 Outside MA Fax 800 227 2659 E mail custserv mfii com Web site www mfii com FORM NO 5 4842 REV B 12 04 Printed in U S A TABLE CONTENTS INTRODUCTION BASIC FUNCTIONING 1 SERVICE 1 INSTALLATION ASSEMBLY 2 SETTING IN PLACE 2 MECHANICAL CONNECTIONS 2 WATER CONNECTIONS seeen 2 INSTALLATION CHECK OUT 2 INITIAL CONTROL SETTINGS 2 COOKER CHECK OUT 2 SHUT DOWN PROCEDURE
10. 5 10 15 30 3 oz 85 g 10 15 25 3 oz 85 0 25 30 30 3 oz 85 g O 3 3 3 3 3 3 3 4 6 7 12 8 12 12 1 1 1 1 1 1 1 1 1 Shrimp 16 20 Ibs 2 1 2 1 3 11 15 50 Green 7 9 kg 65mm 3 oz 85 g Bulk Pack 3 1 2 4 Ibs 2 1 2 1 3 35 45 10 Frozen 1 6 1 8 kg 65mm 6 oz 170 g Bulk Pack 3 1 2 4 165 2 1 2 1 3 25 35 10 Defrosted 1 6 1 8 kg 65mm 6 oz 170 9 OPERATION VEGETABLES RECOMMENDED NO FROZEN PAN SIZE 12 x 20 NUMBER SETTINGS IN COOKED SERVINGS OF PANS ITEM WT PER PAN PERFORATED PER PAN Beans Snap Green 6 Ibs 2 1 2 1 18 22 25 30 or Waxed 2 7 kg 65mm 3 02 85 9 Beets 7 1 2 Ibs 2 1 2 40 50 30 35 2 Diameter 3 4 kg 65mm 3 02 85 9 Broccoli Stalks 6 Ibs 2 1 2 14 18 25 30 1 2 3 4 2 7 kg 65 3 oz 85 g Carrots 9 Ibs 2 1 2 18 21 35 40 Sliced 4 kg 65mm 3 02 85 9 Cauliflower Trimmed 6 Ibs 2 1 2 12 16 30 35 1 1 2 2 2 7 kg 65mm 3 oz 85 g Corn 2 1 2 10 15 12 on Cob Husked 1 doz 65mm Cabbage 1 4 1 6 5 Ibs 2 1 2 14 18 15 20 of Head Cored 2 25 kg 65mm 4 oz 115 g Onions 6 Ibs 2 1 2 20 25 25 30 2 Diameter 2 7 kg 65mm 4 oz 115 g Peas 5 Ibs 2 1 2 5 6 25 30 Shelled 2 25 kg 65mm 3 oz 85 g Potatoes 10 Ibs 2 1 2 18 21 50 French Fry Cut 4 5 kg 65mm 3 02 85 9 5 Potatoes 10 Ibs 2 1 2 35 40 50 Regula
11. BLE SHOOTING 3 Connect an ohmmeter between terminals 1 and 3 4 Rotate timer dial beyond the O 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 Move ohmmeter leads to terminals 1 and 4 Rotate timer dial to 0 Minute position an audible click indicates correct position If zero ohm reading cannot be obtained the timer is defective and must be replaced 7 Remove ohmmeter and replace all five leads on timer terminals as shown in Fig 2 on page 11 TIMER MOTOR A defective timer motor will cause continuous opera tion in the Time mode with the timer dial failing to return to the O Minute position Since thermostatic switch failure can cause the same symptom fault must first be isolated to the timer by testing the ther mostat Refer to cooking compartment thermostatic switch section on page 15 1 Carefully check motor wire leads and tighten loose connections WARNING Use care while working with control panel Termi nals carry 120 volts Turn on power to the cooker Set timer dial any setting beyond O Minute If operation is correct the motor will turn the dial to ward O Minute If the motor fails to operate it is defective and the entire timer must be replaced Shut off power to the cooker DOOR INTERLOCK SWITCH Malfunction of the cooke
12. BUZZER FAILS TO SOUND AT END OF TIMER SETTING A Timer contacts faulty Replace timer Refer to 60 minute timer section on page 13 Replace buzzer Refer to cooking compartment thermostatic switch section on page 15 C Faulty wiring Inspect condition of wire and tightness of all connections Correct as needed 5 STEAM FLOWS CONTINUOUSLY FROM BOILER OR DIRECT CONNECTED STEAM CONTROL DRAIN LINE WITH COOKER IN OPERATION A Cold water not connected Turn on external shut off valve Replace thermostat Refer to cooking compartment thermostatic switch section on page 15 Replace valve Inspect condition of wire and tightness of all connections Correct as needed 12 C Faulty timer motor D Faulty steam solenoid valve B Buzzer faulty B Faulty thermostat C Faulty cold water solenoid D Faulty wiring TROUBLE SHOOTING The electrical trouble shooting procedures that follow require access to components and terminals of the electrical control panel shown in Fig 6 on page 21 Electrical controls are reached by removing screws that fasten the control panel to the frame The panel may be pulled forward for testing while interconnect ed to the cooker circuits or disconnected at the pin connection for complete removal and repair INCOMING POWER Before trouble shooting any of the electrical parts or assemblies verify that power is being supplied to the cooker Incoming power is connected at the boiler or di
13. IRCUITS The plumbing circuits consist of the piping steam so lenoid valves orifice drain and cold water condens er required to provide controlled steam application to the cooking compartments A simplified diagram of these circuits is shown in Fig 2 on page 5 NOTE Fig 2 is strictly a pictorial schematic diagram and is not intended to show the actual configuration of the plumbing All components are shown in correct relationship with each other However the diagram does not show their actual locations or position within the cooker As shown in the diagram steam inlet and exhaust connections are connected at the factory directly into a steam boiler or direct connected steam plumbing enclosed within the base cabinet on which the cooker is mounted The boiler or direct connected steam control system is equipped to supply constant reg ulated steam at 14 15 PSI Steam exhaust having been reduced to water by the cold water condenser PRINCIPLES OF OPERATION is directed into the boiler or direct connected steam control drain system Steam inlet lines for compart ments are equipped with normally closed solenoid valves operated by the electrical control circuits The inlet valves are opened whenever the compartment control circuit is activated by use of the 60 minute tim ers STEAM INLET LINE Asteam supply line is plumbed from the boiler output or direct connected steam control to a 1 2 inch barb fitting connected
14. SHOOTING GUIDES Refer to the trouble shooting guide for use by ser ELECTRICAL FAULT ISOLATION Correction of an electrical failure first requires isola tion of the fault to a single circuit or component In most cases the nature of the failure and its effect upon the operation of the cooker will be sufficient to narrow it down to one or more circuit elements Re fer to the isolating electrical faults table on page 14 ELECTRICALTROUBLE SHOOTING PROCEDURES Before performing the trouble shooting procedures in this section the serviceman must be familiar with the function of all controls as described in the oper ating section as well as with the principles of opera tion section in this manual vice personnel given on page 12 13 GENERAL TROUBLE SHOOTING GUIDE B Door interlock switch contact not closed C Door interlock switch faulty D Indicator light burned out E Faulty timer contacts B Faulty wiring 3 STEAM ENTERS COMPARTMENT CONTINUOUSLY TIMER DIAL NOT TURNING Move knob to timing location Replace switch Refer to cooking compartment thermostatic switch section on page 15 A Constant steam position B Faulty thermostatic switch Replace switch Refer to 60 minute timer section on page 13 Replace switch Refer to steam solenoid valve section on page 15 E Faulty wiring Inspect condition of wire and tightness of all connections Correct as needed 4 STEAM CONTINUES TO FLOW INTO COMPARTMENT AND OR
15. TING PROCEDURES The 3500 Pressureless Steam Cooker defrosts fro zen foods and cooks fresh and defrosted foods Each cooking compartment permits selection of continuous constant steam cooking or timed 0 60 minutes cooking Instructions for operation are included in this section Consult Test Kitchen Bulletin for detailed cooking information OPERATION STEAM SOURCE OPERATION The Pressureless Cooker is supplied mounted on a cabinet containing either a steam boiler or controls for direct connected steam Manual controls are ac cessed by opening the cabinet door The start up procedure for the steam source is completed once before each daily operating period of the cooker For steam boilers see instruction plate PREHEATING Before each initial operation of the cooker and at any other time when the cooking compartment is cold a one minute preheating period is required To preheat the cooker put steam source into operation and pro ceed as follows 1 Close cooking compartment door 2 Set 60 Minute Timer Dial 1 to one minute set ting NOTE Total elapsed preheating time equals the timer set ting plus a short delay period needed to active a thermostatic switch included in the controls 3 Turn off buzzer which sounds to indicate cooking is complete by setting the Timer Dial 1 to OFF position COOKING Before loading the cooker be sure compartment is hot Refer to the preheating section above for i
16. derlined with a perforated pan for best results If they are defrosted first the heating time will be decreased Fresh foods may also be cooked in this unit Vegetables and other foods where the stock is not to be retained should be cooked in perforated 12 x 20 x 2 1 2 pans for the most nutritious results There is a thermostatic time delay built into this unit which adapts the unit to the proper cooking time This means that the total time will usually be longer than the time setting There is a safety microswitch on the door which shuts off the steam each time the door is opened if the unit is in the cooking cycle Both compartments may be filled and timers set simultaneously Total cooking time will vary depending on the load even though the timer setting is the same All foods except cakes and pastry can be cooked in a steam cooking unit Steam cooked meals have greater nutritional value since they retain most of their vitamins and minerals Because foods are cooked faster by the higher temperatures of steam cooking they can be prepared closer to serving time insuring maximum freshness Steam cooked foods have a higher percent yield more portions per dollar spent Food may be served from the same pan in which it is steam cooked thus reducing food breakage since there is no extra handling or transferring of food from cooking pans to serving pans It also reduces pot washing tasks Some important advantages of steam cook
17. he door latch assembly 180 and install into the left door latch mounting holes NOTE Each stud on the latch assembly should have a plastic washer a spring a plastic washer and a Nyloc type nut 10 To adjust the tension of the door latch tighten both nuts down until the springs are fully compressed then back each nut off 1 2 turn 11 Replace the control panel and reconnect the power to the unit 12 Remove the inner door assembly by removing the six screws and spacers on the top and bottom of the door 13 Move the magnet and magnet clip to the opposite side of the inner door panel see fig 5 page 20 14 Put the door back together making sure the mag net is located at the top of the door and refasten it together with the six screws and spacers into the top and bottom of the door 15 Rotate the door 180 for mounting 16 Slide the remaining hinge into the top door bear ing 17 Slide the door and hinge assembly down onto the hinge that you have already mounted to the front of the unit Use the two to mount the top hinge into the right upper hinge mounting holes NOTE Be sure to include spacer washers behind OPERATION OPERATING CONTROLS AND INDICATORS The controls and indicators required to operate the Pressureless Steam Cooker are listed in Table 1 on page 5 together with a short functional description of each Figure 1 on page 5 shows the physical location of each control and indicator OPERA
18. ht is verified by using an AC volt meter at the leads with input power on the selector switch in the 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 or control components selec tor switch timer or door switch COOKING COMPARTMENT THERMOSTATIC SWITCH A thermostatic switch included in the circuit for the timer motor delays timer operation until steam flowing into the compartment satisfies the temperature actu ated switch device If a timer motor fails to operate within about one minute after the indicator light comes on with cooker compartment empty the cause may be a defective thermostatic switch To test the switch proceed as follows 1 Disconnect the two wires connected to the thermo static switch terminals 2 Connect an ohmmeter between the two terminals of the switch 3 Place the cooker into operation and observe ohm meter dial Within one minute of operation the switch contacts close automatically to register a zero ohm reading on the dial If a zero ohm reading TROUBLE SHOOTING is not obtained the switch is defective 4 Shut off cooker disconnect ohmmeter leads and replace wires on switch terminals BUZZER If the buzzer does not sound at the termination of the operator selected timer setting timer dial returned to O Minute p
19. in the OFF position and the compartment doors are open Consult the steam boiler instruction plate and complete the shut down procedures for the boiler REVERSING THE DOORS The Pressureless Steam Cooker has a reversible cooking compartment door This section contains in structions for reversing this door 1 Open the cooking compartment door 2 Remove the two screws that attach the top hinge to the front of the unit 3 Slide the door upward off the bottom hinge 4 Remove the two screws that attach the bottom hinge to the front of the unit 5 Remove the plastic hole plugs from the front of the unit Push the black hole plugs into the left up per and lower hinge mounting holes 6 Reinstall the top hinge with spacers and screws into the right lower hinge mounting hole Rotate the hinge 180 for installation so that the pin that the door rides on is now facing UP 7 Remove the door latch assembly from the face of the unit The two nuts mounting the door latch are located behind the face of the unit and must be accessed by removing the control panel First shut off the power to the unit at its source then remove the control panel by unscrewing the eight mounting screws and pulling the panel away from the front frame 8 Remove the two white hole plugs from the left door latch mounting holes and insert them into the right door latch mounting holes where the door latch assembly was originally mounted 9 Rotate t
20. ing are labor saving reduced operating costs space saving and the lifting of heavy stock pots is eliminated Rice and spaghetti products if thoroughly wet at the start of the cooking process are very easily pre pared Food such as potatoes poultry seafood and some meats may be blanched in the steam cooker thus reducing the total cooking time and grease absorption Fuel is used only when the steam cooking unit is in operation The steam cooker will loosen foods burned on pans making washing easier Solid pans are recommended when liquid is to be retained and perforated pans when the liquid is not to be retained Eggs may be cooked out of the shell if they are to be chopped which eliminates peeling after steaming The steam cooker can be opened during the cooking period to add or remove items If any time is lost and adjustment may be make on the timer Steam cooking information including recommended pan size and type weight per pan cooking times and pan yields are given on the following pages of this bulletin OPERATION PRESSURELESS STEAM COOKING TIMER SETTINGS The 3500 Pressureless Cooker is a two compartment unit Each compartment holds five 12 x 20 x 2 1 2 or three 12 x 20 x 4 pans This unit enables the cook to prepare foods close to the time of service The cooking times given are timer settings and should be set on a preheated compartment There is a thermostatic time delay in each compartment that adjus
21. ion controls for the cooker The assembled unit is shipped bolted to a skid with cabi net feet in a separate container Steps required for assembly are as follows 1 Remove the four bolts that fasten the equipment frame to the skid 2 Install feet in threaded mounting locations of the cabinet frame 3 Mount the two baffles on studs located on the right inside of the cooking compartments 4 Mount the four pan support racks in brackets inside control compartments 5 Attach panels to lower cabinet Detailed instruc tions are enclosed with the panels 6 Attach the drip trough on studs located on the face of the unit SETTING IN PLACE The location of installation must be under an exhaust hood which will remove small amounts of water va por emitted when the cooker doors are opened and exhaust fumes from the air Level the unit in final loca tion by turning the adjustable feet Using the cabinet top as a reference obtain level adjustment left to right and front to back MECHANICAL CONNECTIONS Since the Pressureless Cooker is interconnected at the factory to the steam boiler or direct steam plumb ing no field connections to the cooker are required All electrical and plumbing connections are routed to the steam boiler cabinet through the 6 inch high space between the floor and the bottom edge of the cabinet frame Connection locations for the cooker mounted on steam boilers of electric gas and steam coil utility
22. n on page 1 PREVENTIVE MAINTENANCE A good preventive maintenance program begins with 16 the daily cleaning procedure described in the cleaning section on page 4 Additional preventive maintenance operations are presented in this section In establish ments that employ full time maintenance personnel the tasks described can be assigned to them For oth er installations tasks requiring mechanical or electri cal experience should be performed by an authorized service agency The following paragraphs set forth minimum preven tive maintenance procedures that must be completed periodically to assure continued trouble free opera tion of the cooker MAINTENANCE CAUTION Under no circumstances should hardware or parts be replaced with a different length size or type other than as specified in the parts list The hardware used in the cooker has been selected or designed specifi cally for its application and the use of other hardware may damage the equipment and will void any war ranty COOKING COMPARTMENT CLEANING A daily cleaning of the cooking compartments and pan supports is required See cleaning section on page 4 for details REPAIR AND REPLACEMENT Refer to Illustrated parts section of this manual con tains a listing of all replaceable parts and associated exploded views of the 3500 Cooker In most cases disassembly procedures will be obvious from the ex ploded views Instructions follow for procedures tha
23. nstruc tions 1 Slide pans of food into cooking compartment pan supports 2 Close cooking compartment door 3 Set timer cooking time a Constant steam for continuous cooking b 60 minute timer for timed cooking 4 Set appropriate timer to the required cooking time see Test Kitchen Bulletin 59 5 Turn off buzzer which sounds to indicate cooking is complete by setting timer dial 1 to the OFF posi tion 6 Open door sightly at first letting most of the steam out of the compartment and then fully open the door 7 Unload by sliding pans of food from pan supports taking care to avoid hitting compartment opening SHUT DOWN PROCEDURE No shut down procedure is required for the cooker except to check that both timer dials 1 are in the OFF position and that both compartment doors are open When all cooking has been completed for the day the steam source must be shut off For steam boilers see instruction plate CAUTION When the unit is not in use leave the cooking com partment door slightly ajar to prolong the life of the door gasket CLEANING After each period of daily operation more frequent ly as required to maintain cleanliness the cooker should be thoroughly cleaned by completing the fol lowing steps 1 Remove left and right side pan supports baffles and drain screens by lifting up and off mounting studs Wash with a mild detergent Rinse and set aside for reassembly 2 Wash c
24. ntacts switch to shut off the cooking operation and sound a signal buzzer The buzzer is silenced by returning the timer dial to the OFF position In the constant steam mode operation will be continuous Steam emitted from the compartment along with liquid cooking drainage is directed through a drain screen inside the compartment into the cooker drain line Acold water solenoid valve connected into the cooker drain line is automatically actuated by a thermostatic switch in the boiler drain to condense the steam to water prior to discharge into the boiler drain SERVICE Required service both preventive and corrective is explained in Section 6 Should repairs be required a network of authorized agencies is available to assist with prompt service A current Directory of Authorized Service Agencies may be obtained by contacting Market Forge Industries Inc 35 Garvey Street Everett Massachusetts 02149 4403 Telephone 617 387 4100 Toll Free 866 698 3188 Fax 617 387 4456 Outside MA Fax 800 227 2659 Parts Price Service Telephone 888 259 7076 www mfii com The model and serial numbers must be referenced when corresponding with Market Forge The data plate containing the serial number pertain ing to the equipment is located on the lower front trim of the cabinet INSTALLATION ASSEMBLY The Pressureless Cooker is factory mounted on a cabinet base containing either a steam boiler or di rect steam connect
25. on unless the door is closed The buzzer is an alarm device that operates by oscil lation of a striker against the core of an electromag THERMOSTATIC SWITCH net When the 60 minute timer dials reach the O Min The thermostatically operated switch is a two posi ute position the buzzer coil is energized to sound tion normally open switch mounted on the cooking the buzzer Movement of the timer dial to the OFF compartment The switch functions to activate the position opens the contact to the buzzer coil to shut cold water solenoid valves of the steam condensing it off system and to delay timer motor operation until the compartment temperature reaches 195 F thus as DOOR INTERLOCK SWITCH suring that cooking temperature exists throughout the The interlock switch is a single pole proximity switch timed duration with normally open contacts The switch is operated 11 TROUBLE SHOOTING GENERAL The information in this section is intended to assist both the operator and service personnel in locating the general source of problems that may occur with the cooker Before following any of the procedures given in this section the operator should be thor oughly familiar with the operating instructions and the function of all controls that are described in the operating section of this manual If the problem can not be readily corrected the operator should contact the nearest Market Forge service agency for assis tance TROUBLE
26. ooking compartment interior using a mild detergent and water Rinse and dry thoroughly 3 Replace pan supports baffles and drain screens in compartment and leave door open DRAINAGE O COOKING COMPARTMENT DRAINAGE The bottom of the cooking compartment is angled slightly toward the rear of the unit This assures that any condensate build up or spills will be directed to ward the drain hole which is located at the rear bot tom center of the cooking compartment Any liquid exiting the cooking compartment runs down the cook ing compartment drain tube and into the drain line DRIP SPILL TROUGH DRAINAGE The 3500 Pressureless Steam Cooker has drip spill trough below the cooking compartment door It will catch any condensate gathering on the front of the unit when the door is opened OPERATION TABLE 1 CONTROLS amp INDICATORS Refer to Fig 1 ITEM DESCRIPTION FUNCTION 4 Timer Constant Steam Controls cooking up to 60 minutes for uses constant operation Indicator Light Red lit that the cooker is Buzzer Not Shown Signals end of cooking period CONVECTION STEAM COOKER Fig 1 Control Panel 0079 11 12 13 14 15 16 17 18 19 20 21 OPERATION TEST KITCHEN BULLETIN MODEL 3500 PRESSURELESS COOKER FACTS ON PARADE Frozen vegetables should always be cooked in perforated 12 x 20 x 2 1 2 pans 7 1 2 165 34 kg maxi mum per pan Frozen entrees should be un
27. or begins to time out When the timer motor has operated for the preset duration the common element is transferred to contact 4 return ing the inlet solenoid valve to the closed position and energizing the buzzer Contact to the buzzer circuit remains closed until the dial is manually turned to the OFF position returning the common element 1 of the timer switch to the neutral position PRINCIPLES OF OPERATION INLET SOLENOID VALVE EN STEAM INLET WATER INLET 7 FROM BOILER FROM STEAM SOURCE N I INLET SOLENOID VALVE STEAM INLET FROM STEAM SOURCE WATER GOING TO DRAIN LINE WATER GOING DRAIN LINE CONDENSING SOLENOIDS N Fig 2 Pictorial Diagram Steam and Water Circuits INDICATOR LIGHTS by the proximity of a magnet within the door When An indicator light is included for both compartments the door is open the switch contacts remain in the The light remains on red at all times when the co open position When the door is closed and secure inciding timer dial is set and the door interlock switch ly latched in place the magnet is near the switch to is closed The light turns off at the end of the timed close the contacts Connected between the operating cooking duration contact 3 of the timers and the steam inlet solenoid valve the door switch acts as a protective device to BUZZER interrupt valve operati
28. osition the fault may be a defective buzzer Buzzer operation is verified using an AC volt meter at buzzer coil connections with input power on and selector switch and coinciding timer dial set at the O Minute position If voltage is 120 volts the fault is in the buzzer which must be replaced If 120 volts is not present the fault is in the wiring or control compo nents timer or selector switch COLD WATER CONDENSER CIRCUIT If during cooker operation steam exits from the drain line opening located in lower boiler compartment and the condensing system fails to operate as evidenced by repeated discharge of water from the drain line the condensing circuit is malfunctioning The failure can be caused by a defective condenser thermostat or cold water solenoid coil or by wiring failure To test condenser thermostat refer to cooking compartment thermostatic switch section on page 15 If the condenser thermostat functions correctly but ei ther of the cold water solenoid valves fails to operate the cause might be a faulty valve coil A defective coil is found using an AC volt meter to check the voltage at the coil wire terminals with the cooker compartment in operation If voltage of 120 volts is present and the valve fails to open the fault is in the valve coil Defec tive valve coils are separately replaceable WIRING All of the electrical components of the cooker timers indicator lights etc are connected to each
29. other by wiring shown in Fig 2 on page 11 If all of the electrical components are operating cor rectly and the incoming power has been checked but the cooker fails to operate the fault lies in the wiring Fig 2 on page 11 is a diagram that shows all ter minals and interconnections within the electrical cir cuits All numbered terminals are identified and all leads number coded as shown Connections can be easily removed Figure 3 on page 14 also shows the schematically information and is an aid in isolating circuits for test ing Using an ohmmeter wiring continuity between the connections shown on the wiring diagram Fig 2 page 11 is readily verified This is best done in stages removing only those wires required for each continuity check As each lead is replaced 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 MAINTENANCE GENERAL This section contains both preventive and corrective maintenance information Preventive maintenance may be performed by maintenance personnel at the establishment in which the cooker is installed It is recommended that user personnel never attempt to make repairs or replacements to the equipment with out the assistance of authorized service Assistance in service methods or a current Directory of Autho rized Agencies may be obtained from Market Forge Refer to service sectio
30. r Cut 3 4 5 kg 65mm 3 02 85 9 Spinach 3 Ibs 2 1 2 1 3 3 10 12 Cleaned Cut 1 4 kg 65mm 3 3 4 oz 105 g Squash Summer 7 Ibs 2 1 2 7 10 30 35 Sliced 1 thick 3 2 kg 65mm 3 oz 85 g Squash 9 Ibs 2 1 2 1 3 10 15 25 30 Winter Peeled 4 kg 65mm 3 oz 85 g Turnip 5 Ibs 2 1 2 1 3 28 32 20 25 Dice 2 25 kg 65mm 4 oz 115 9 CANNED VEGETABLES Canned 7 Ibs 2 1 2 1 3 5 10 25 30 Vegetables 3 2 kg 65mm 3 oz 85 g MISCELLANEOUS Eggs 3 dozen 2 1 2 1 3 9 11 36 in Shell 65mm 1 Egg Each Eggs 4 dozen 2 1 2 1 3 48 out of Shell 65mm 1 Egg Each 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 Rice 4 Ibs 2 1 2 1 2 18 22 60 65 See Bulletin 16 1 8 kg 65mm 3 oz 85 g Spaghetti 3 Ibs 2 1 2 1 2 18 22 40 45 See Bulletin 13 1 4 kg 100mm 4 oz 115 9 OPERATION MEAT POULTRY FISH Chicken FROZEN WT PER PAN PERFORATED Chicken 4 Ibs 3 each 4 1 3 Whole 100 mm Fowl 5 Ibs or more 2 each 4 Whole 100 mm Fish Fillets 15 Ibs 2 1 2 6 8 kg 65mm Meatloaf RECOMMENDED PAN SIZE 12 x 20 8 Ibs 2 1 2 1 3 6 kg 65mm 3 Ibs 21 2 10 15 12 15 1 4 kg 65mm 2 02 559 3 1 3 1 3 1 3 1 3 1 3 1 3 5 Ibs 2 1 2 Frankforts 2 3 kg 65mm Hamburgers 5 Ibs 2 1 2 3 oz 85 9 2 3 kg 65mm Meatballs 6 Ibs 2 1 2 1 oz 30 g size 2 7 kg
31. r door interlock switch pre vents timer indicator lights from turning on and steam solenoid from opening when the timer dial is set If steam does not enter the compartment and the indi cator 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 wires to the door switch terminals see Fig 2 page 11 15 3 Connect an ohmmeter between the terminals of the switch 4 Actuate the switch by closing the cooking compart ment door If a zero reading cannot be obtained the switch is defective and must be replaced 5 Remove the ohmmeter and replace the leads on switch terminals see Fig 2 page 11 STEAM SOLENOID VALVES When either inlet solenoid valve fails to operate the fault may be a defective coil A defective coil is found using an AC volt meter to check the voltage at the coil wire terminals with the cooker compartment operat ing in either constant steam or 60 minute timer mode If voltage of 120 volts is present and the coil fails to open the valves the fault is in the valve coil Defec tive valve coils are not separately replaceable requir ing complete valve replacement 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 indica tor light A burned out or defective lig
32. rect connected steam control box located in the base cabinet With power connected to the cooker an AC volt meter is used to measure 120 volts across L1 and L2 If 120 volts is present and the cooker will not operate the fault lies within the electrical circuits of the cooker ELECTRIC INSPECTION The first step in any electrical trouble shooting pro cedure is a thorough physical inspection of all wiring connections WARNING Before removing control panel or checking connec tions and wiring be sure that the circuit breaker for in coming power is OFF When power is supplied all ex posed terminals of the control panel carry 120 volts Check all wiring connections by hand to assure that both ends of all connection points are tightly secured Use a screwdriver to tighten connection points If nec essary visually inspect all quick disconnect terminals for evidence of corrosion Terminals in this condition should be separated cleaned with emery cloth until shiny and tightly reconnected 60 MINUTE TIMER O TIMER CONTACTS Defective timer contacts will result in failure of either cooker compartment to operate When this occurs remove the control panel and proceed as follows 1 Turn off power to the cooker at external circuit breaker 2 Disconnect all five wires from timer terminals see Fig 2 page 11 ELECTRICAL FAULT ISOLATION GUIDE FAILURE FAULT LOCATION 1 Will not operate in either constant steam or 60 min
33. sist ing of two independently controlled compartments enclosed in a single cabinet Each compartment is equipped with a separate three piece door with inner gasket plate isolated from the exterior surface Door latches operate by action for positive sealing of inner door Steam and steam condensing circuits are electrically controlled Operating controls are dis played on a single front mounted panel and include separate timers with indicator lights for selection of constant steam or 60 minute long duration cooking Aseparate steam source required for operation of the Pressureless Cooker is normally purchased with it please refer to the respective manual for guidance BASIC FUNCTIONING The Model 3500 may be operated with only one compartment in use or both may be used simultane ously Each compartment is equipped with identical controls allowing selection of constant steam or 60 minute timer operation The cooker becomes operational when it is set to con stant steam or the timer is set at the desired cooking time and the compartment door is closed The indi cator light comes on and the steam solenoid valve opens allowing steam to flow into the compartment When steam flowing inside the compartment has raised the interior temperature to 195 F the contacts of a thermostatic switch automatically close complet ing the circuit to the timer motor and starting the cook ing time period At the end of the set interval timer co
34. supply 15 PSI steam to the steam inlet line for the cooker 1 All steam boiler controls are in the operating mode and 15 PSI steam is applied to the cooker inlet plumbing 2 Cooker timers for both compartments Figure 1 page 5 are in the OFF position 3 Cooker compartments are empty of all information materials pan supports are mounted in place and doors are open COOKER CHECK OUT The cooker check out procedures are as follows 1 With the doors open set timers to about the 4 min ute position Observe that indicator lights are off and steam does not enter compartments 2 Close cooker compartment doors Observe that indicator lights turn on and steam can be heard rushing into the compartment simultaneously with the door closing 3 Observe the boiler drain line for passage of steam into the open floor drain Correct steam condenser operation is evidenced by presence of water flow INSTALLATION ing from the drain line 4 Observe cooker operation for several minutes Op eration is correct if timer dials begin to rotate after a short delay period required for preheating After the delay period plus the 4 minute initial setting the timer dials will return to the O minute position at which a buzzer sounds The buzzer is silenced by turning the dial to the OFF position SHUT DOWN PROCEDURE No shut down procedure is required for the Pressure less Cooker except to check that all timer dials 2 are
35. t are not readily apparent DOOR LATCH TENSION ADJUSTMENT CAUTION Shut off main electrical power to unit 1 Open the cooking compartment door 2 Remove the control panel by removing the eight mounting screws and disconnecting the wire plug and restraining wire 3 Tighten both nuts down until the springs are fully compressed 4 Back each nut off 1 2 turn 5 Remount the control panel reconnecting wire plug and restraining wire ILLUSTRATED PARTS LIST GENERAL This section contains a complete listing of all re placeable parts of the 3500 For the purpose of parts identification the unit is broken down into functional assemblies and each assembly is shown in an ex ploded view that is keyed to the accompanying parts list Each parts list contains the figure index number the Market Forge part number and an abbreviated description ORDERING INFORMATION Orders for repair parts should be directed to the near est authorized parts distributor For a current Market Forge Authorized Parts Distributor List con tact 17 Market Forge Industries Inc 35 Garvey Street Everett Massachusetts 02149 4403 Telephone 617 387 4100 Toll Free 866 698 3188 Fax 617 387 4456 Outside MA Fax 800 227 2659 Parts Price Service Telephone 888 259 7076 www mfii com All orders should contain the Market forge part number s the part description s and the model and serial number of the cooker for which the part or
36. to the input sides of both steam inlet solenoid valves When a cooking compartment is not in use the valve for the compartment remains closed to prevent steam from entering During operation the appropriate inlet solenoid valve is opened by activa tion of the control circuit Steam is projected onto the surface of pans of food loaded into the compartment by an orifice located inside the compartment Steam continues to flow through the compartment in this manner until the con trol circuit closes the solenoid valve STEAM EXHAUST AND DRAIN LINES Perforated strainers at the drain line openings inside each compartment allow only steam condensation and liquid cooking drainage to enter Prior to dis charge into the boiler drain system steam is convert ed to water by the cold water condensing systems for each compartment STEAM EXHAUST CONDENSING SYSTEM The steam condensing system consists of the identi cal two position normally closed cold water solenoid valves with outlet sides connected into the exhaust plumbing for each cooking compartment A spray nozzle directs cold water about the inside of the drain lines to increase cold water contact with exhausted steam Valve inlet sides are connected remote from the sup ply line of the steam boiler or direct connected steam plumbing The valves respond to a thermostatic 10 switch located inside the compartment When the timer starts the cold water solenoids will energize
37. ts the total time depending on the temperature and amount of the food Therefore the total time will be greater than the timer setting At the end of the timer cooking cycle the bell will ring steam will stop flowing and the food can be removed FROZEN VEGETABLES APPROX RECOMMENDED NO FROZEN PAN SIZE 12 x 20 NUMBER SETTINGS IN COOKED SERVINGS ITEM WT PER PAN PERFORATED OF PANS PER PAN Asparagus 7 1 2 Ibs 2 1 2 3 12 15 30 Spears 3 4 kg 65mm 3 oz 85 g Beans Green 6 Ibs 2 1 2 3 10 15 25 Regular 2 7 kg 65mm 3 oz 85g Beans Green 6 Ibs 2 1 2 3 5 7 25 French Cut 2 7 kg 65mm 3 02 85 9 Beans 7 1 2 165 2 1 2 12 15 Lima 3 4 kg 65mm 3 02 85 9 6 Ibs 2 1 2 Broccoli 2 7 kg 65mm Brussel 7 1 2 Ibs 2 1 2 Sprouts 2 7 kg 65mm 6 Ibs 2 1 2 Carrots 2 7 kg 65mm 6 Ibs 2 1 2 Cauliflower 2 7 kg 65mm 7 1 2 Ibs 2 1 2 Corn Cut 3 4 kg 65mm 7 1 2 Ibs 2 1 2 1 8 Mixed Vegetables 3 4 kg 65mm 3 oz 85 g 7 1 2 Ibs 2 1 2 1 3 3 5 30 Peas Loose 3 4kg 65mm 3 oz 85 g 9 Ibs 2 1 2 1 3 Must be 30 Spinach 4kg 65mm Defrosted 4 oz 115 g 12 Ibs 2 1 2 1 3 Must be 50 Squash 5 4 kg 65mm Defrosted 3 02 85 9 FROZEN PREPARED ENTREES Lobster Tails 7 8 Ibs 2 1 2 1 3 15 25 15 6 8 oz 170 255 g 3 2 3 6 kg 65mm 6 oz 170 g Shrimp 16 20 Ibs 2 1 2 1 3 8 11 75 7 9 kg 65mm 3 02 859 3 oz 85 g 30 2
38. ute timer A Incoming power B Timer C Door interlock switch relay D Wiring 2 Operating in constant steam position but not in 60 minute timer A 60 minute timer B Wiring 3 Operating in 60 minute timer position but not in constant steam A Timer B Wiring 4 Steam solenoid valve fails to open with indicator light on A Solenoid valve coil B Wiring 5 Indicator light off with steam solenoid valve open A Indicator light B Wiring 6 With indicator light off steam solenoid valve open timer dial fails to turn A Compartment thermostatic switch B Constant steam position C Timer motor D Wiring 7 Buzzer fails to sound at end of 60 minute timer mode A 60 minute timer contacts B Buzzer C Wiring 8 Steam flows continuously form boiler drain line A Thermostatic switch B Cold water solenoid valve C Wiring TO FRONT FRAME GRD STUD TROUBLE SHOOTING 58 RELAY R3 RELAY R4 56 60 62 50 F R N 14 13 14 13
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