Market Forge Industries STP-6G Installation And Operation Manual Download | Manualshive

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6. Maintenance

Table 6.1 - Exterior Sheetmetal Cover

Panels and

Fasteners Ports List

ITEM QTY. DESCRIPTION PART NO.

1

4

Leg, black, adjustable

El 0-0631

2

1

Front Cover Panel Assembly

E91-5767

3

1

Rear Cover Panel Assembly

E91-5789

4

1

Removable Vent Hatch

E91-5777

5

2

Side Cover Panel Assembly

E9I-5778

Fasteners

22

8-32 slotted truss head machine screw, 3/8" long, stainless steel

E08-3492

MARKET

FORGE

INDUSTRIES, INC

35 GARVEYSTREET EVERETT, MA 02149

TEL 617 387

A

100 TELEX: 94-94 I 4

6.2

FAX 61 7 387 4456 OUTSIDE MA 800 227 2659

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Summary of Contents for STP-6G

Page 1: ...ed in the event the user smells gas This information shall be obtained by consulting the local gas supplier MARKET FORGE INDUSTRIES INC 35 GARVEY STREET EVERETT MA 02149 4403 TEL 6173874100 TELEX 94 94 1 4 FAX 617 387 4450 OUTSIDE MA 800 227 2659 FORM NO S 2465 REV B 12 9 96 PRINTED IN USA ...

Page 2: ...Daily Cleaning 4 4 4 3 Daily Cleaning 4 5 4 4 Prolonged Shut Down Cleaning 4 5 5 TROUBLESHOOTING 5 1 General 5 1 Troubleshooting Table 5 1 5 5 5 2 Water Level Control Board 5 6 6 MAINTENANCE 6 1 General 6 1 6 2 Daily Cleaning 6 1 6 3 Preventative Maintenance 6 1 Figure 6 1 Assembly of Exterior Sheet Metal Panels to Unit 6 2 Table 6 1 Assembly of Exterior Sheet Metal Panels Parts List 6 2 6 4 Clean...

Page 3: ...6 9 Blower Box Parts List 6 21 6 10 Solenoid Fill Valve Screen Service 6 22 Table 6 10 Tempering Tank Parts List 6 22 Figure 6 10 Tempering Tank Assy 6 23 Figure 6 11 Gas Tubing Assy 6 24 Table 6 1 I Gas Tubing Parts List 6 5 Figure 6 12 Chassis Assembly 6 26 Table 6 12 Chassis Assy Parts List 6 27 Table 6 13 Tubing Routing List 6 28 Figure 6 13 Tubing Routing 6 29 MARKET FORGE INDUSTRIES INC 35 G...

Page 4: ... AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT 1 2 DESCRIPTION The Steam Tech Plus is a pressureless steam cooker consisting of two independently controlled cooking compartments in a single cabinet Each compartment has its own Independent control panel consisting of a power switch mode select switch constant steam switch timer mechanical or electronic steam ...

Page 5: ...nd will maintain a safe internal holding temperature The unit will now act as a holding cabinet until you call for steam again During this time the generator will continue to idle at 193 F The CONSTANT STEAM button overrides the MODE SELECT switch and the TIMER When the button is depressed the green constant steam light is illuminated In this mode the generator will constantly supply steam as cont...

Page 6: ...ectory of Authorized Service Agencies may be obtained by contacting Product Service Department Market Forge Industries Inc 35 Garvey Street Everett Massachusetts 02149 Telephone 617 387 4100 The model and serial numbers must be referenced when corresponding with Market Forge The data plate containing the serial number is located on the top of the unit An electrical diagram is located on pages 6 8 ...

Page 7: ...any objects on or directly against the unit that will block air openings into the combustion chamber Minimum clearances from both combustible and non combustible surfaces are 2 51 mm from right side wall 2 51 mm from left wall and 6 152mm from rear wall Suitable for installation on combustible floors This unit is serviceable almost entirely from the front Do not install in such a manner that a ser...

Page 8: ...nit so that the Flue is under an exhaust hood to remove the products of gas combus tion DO NOT TOUCH FLUE The Flue reaches extremely high temperatures 1 4 SERVICE CONNECTIONS All service connections are made at the bottom of the unit in the 6 inch high space between the floor and the bottom of the cabinet Please see Figure 2 1 and Table 2 1 for service connections details and dimensions NOTE If th...

Page 9: ...t the gas line into the bottom inlet side of the gas supply shut off valve The supply pressure must be at least I 25mm water column higher than the manifold or regulator pressure for proper functioning of the regulator If it is not check the supply pipe for blockage or excessive pressure drop and make the necessary corrections Perform a gas leak test of all newly made joints as well as those leadi...

Page 10: ...door latch assembly from the face of the unit The 2 door latch mounting nuts are located behind the face of the unit and must be accessed by removing the large side panels 9 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 10 Rotate the door latch assembly 180 and in...

Page 11: ...l the solenoid valves will close and the burner will Ignite After a short time approximately 5 minutes the green READY light will come on indicating that the unit is ready to make steam 3 3 STEAM DEMAND Due to the unique nature of this design it is important to understand what the STEAM DEMAND system does The STEAM DEMAND system is the means by which the Steam Tech Plus monitors and creates steam ...

Page 12: ...STANT STEAM MODE The CONSTANT STEAM button overrides all other cooking modes When the CONSTANT STEAM button is depressed the CONSTANT STEAM window located next to the CONSTANT STEAM button will light up green Immediately the STEAM ON window located near the top of the control panel should light up green At the same time the STEAM DEMAND window should light up red After a short time the red STEAM D...

Page 13: ...hutting the unit down Simply press the POWER switch into the OFF position All indicator lights on the control panel will go out and the generator for that cooking compartment will drain The tempering tank will not drain until both POWER switches are in the OFF position CAUTION When the unit is not in use leave both cooking compartment doors slightly ajar to extend the life of the cooking compartme...

Page 14: ...come on 4 2 2 Cooking NOTE The green READY light must be on before any controls become operational 1 Slide pans of food into the cooking compartment pan support racks 2 Firmly close the cooking compartment door 3 Select a cooking cycle either timed or untimed 4 For timed cooking set the MODE SELECT switch to the desired cooking mode and set the TIMER to the desired cook time 5 At the end of a time...

Page 15: ... POWER switches ore in the OFF position When a cooking compartment Is not in use be sure to leave its door slightly ajar to extend the life of the cooking compartment door gasket When the unit is completely shut down both cooking compartment doors should be left ajar NOTE To avoid the unintentional creation of steam upon startup return both timer knobs to the OFF position and be sure that both CON...

Page 16: ...dicator Located above the Steam On indicator Lights up red as the product you are cooking calls for steam It will cycle on and off at varying rates depending on the quantity and product being cooked Hold Indicator Located near the center of the control panel on the left side Lights up amber when the unit is in the HOLD mode Temperature Gauge Located on the right side of each of the steam hoods abo...

Page 17: ...h Screen E91 5769 4 1 Left Pan Slide E91 5700 5 1 Right Pan Slide E91 5698 NOTE The components and quantities shown on this page are for a single cooking compartment only These components and quantities are identical for both the upper and lower cooking compartments MARKET FORGE INDUSTRIES INC 35 GARVEY STREET EVERETT MA 02149 4 4 TEL 617 387 4100 TELEX 94 94 I 4 FAX 6 1 7 387 4456 OUTSIDE MA800 2...

Page 18: ...to drop down into position 8 Replace drain screen onto rear wall of cooking compartment by sliding it down onto its mounting tabs 9 Replace a la carte tray by sliding it back until it drops down onto its mounting pins 10 Replace pan supports into cooking cavity by hanging them on their mounting brackets 8e sure to hang the support with the metal baffling on it on the right steam inlet opening side...

Page 19: ...ator and or tempering tank very slowly 1 Dirty strainer screen in the water fill solenoid valve 2 Dirt or lime accumulation on seat of water fill solenoid valve 1 Clean replace strainer screen 2 Clean valve seat Steam generator will not fill 1 Faulty generator fill solenoid valve 2 Faulty generator drain solenoid valve 1 If 120 Volt is verified at the solenoid coil but the valve fails to open repl...

Page 20: ...ignitor 6 Check electrical connections Be sure ignitor gap is 1 8 Check ignitor alignment Be sure ignitor is seated properly in its mounting Warm Up Burner will not stay lit 1 Faulty ignition flame sensor control module 1 See Ignition Flame Sensor Control Diagnostic section 2 Faulty ignitor flame sensor 2 Check etectrical connections Be sure ignitor gap is 1 8 Check ignitor alignment Be sure ignit...

Page 21: ...ure ignitor gap is 1 8 Check ignitor allignment Be sure ignitor is seated properly in its mounting 6 Faulty Main burner solenoid on gas regulator valve relay 6 Check Main burner solenoid relay Replace if necessary 7 Faulty Main burner solenoid on gas regulator valve 7 If 24 volts is verified at the solenoid coil but valve fails to open replace gas regulator 8 Faulty pressure switch 8 Check replace...

Page 22: ... of this manual Steam Suppression not functioning Excess steam comes out of the cooking compartment when the door is opened 1 Dirty strainer screen in the spray nozzle solenoid valve 2 Dirt or lime accumulation in the generator spray nozzle 1 Clean or replace strainer screen 2 Clean generator spray nozzle 3 Faulty timer which controls spray nozzle water solenoid valve 3 Check to be sure that timer...

Page 23: ...at the generator drain line is not kinked and is free of debris 2 Check to be sure the generator drain hole is free of debris 3 Rebuild or replace generator solenoid drain valve Tempering tank doesn t drain when both POWER Switches are in the OFF position 1 Clogged tempering tank drain line 2 Clogged tempering tank drain hole 3 Faulty tempering tank solenoid drain valve 1 Clean or replace temperin...

Page 24: ...lligator clips Procedure 1 Turn off all power to the unit 2 Select the controller to be tested Inside the electrical panel the water level control for the top cooking cavity is at the top of the electrical panel and wires to the controller will have an A after the wire number The controller for the bottom cooking cavity is at the bottom of the electrical panel and its wires will have a B suf fix I...

Page 25: ...til the screen is free to drop down into position 8 Replace drain screen onto rear wall of cooking compartment by sliding it down onto its mounting tabs 9 Replace a la carte tray by sliding it back until it drops down onto its mounting pins 10 Replace pan supports into cooking cavity by hanging them on their mounting brackets Be sure to hang the support with the metal baffling on it on the right s...

Page 26: ... Panel Assembly E91 5767 3 1 Rear Cover Panel Assembly E91 5789 4 1 Removable Vent Hatch E91 5777 5 2 Side Cover Panel Assembly E9I 5778 Fasteners 22 8 32 slotted truss head machine screw 3 8 long stainless steel E08 3492 MARKET FORGE INDUSTRIES INC 35 GARVEYSTREET EVERETT MA 02149 TEL 617 387 A 100 TELEX 94 94 I 4 6 2 FAX 61 7 387 4456 OUTSIDE MA 800 227 2659 ...

Page 27: ... connected to the steam generator 3 Pour 1 2 gallon of Market Forge s TOTAL CON CEPT de liming solution directly into the open side wall port This will immerse the generator interior and water level probes in the solution CAUTION Read directions and information on TOTAL CONCEPT de liming solution before using 4 Wait two hours for TOTAL CONCEPT de liming solution to work Other de liming solutions m...

Page 28: ...cal exhaust duct is the one on the right 7 Using detergent and a damp cloth wipe clean the inside of the vent access hatch 8 Reinstall vent access hatch onto rear of unit 9 Using detergent and a damp cloth wipe clean the inside of the upper and lower steam vent hoods located on the front of the unit just above each of the cooking compartments 10 Reconnect 120v power supply 11 Reconnect the gas ser...

Page 29: ...e Block 08 6520 8 2 Signal Transformer 08 6450 3 2 Gas Ignition Control 08 6542 9 2 Push Button Switch 08 6517 4 1 Grounding Lug 10 5220 10 1 Terminal Block Assembly 08 6519 5 2 Control Board 08 6536 11 2 Terminal Block 08 6518 6 4 DIN Rail Retainer Clips 08 6516 12 4 Relay SPDT 10 9174 MARKET FORGE INDUSTRIES INC 35 GARVEY STREET EVERETT MA 02149 6 5 TEL 617 387 4100 TELEX 94 9414 FAX 6173874456 ...

Page 30: ...6 Maintenance Principles of Operation Schematic MARKET FORGE INDUSTRIES INC 35 GARVEY STREET EVERETT MA02149 TEL 6 I 7 387 4 100 TELEX 94 94 I 4 FAX 617 387 4456 OUTSIDE MA800 227 2659 ...

Page 31: ...6 Maintenance Single Compartment System Wiring Diagram MARKET FORGE INDUSTRIES INC 35 GARVEY STREET EVERETT MA 02149 TEL 61 7 387 4100 TELEX 94 94 1 4 FAX 0 I 7 387 800 OUTSIDE MA 800 227 2659 ...

Page 32: ...6 Maintenance Single Compartment System Wiring Diagram MARKET FORGE INDUSTRIES 1NC 35 GARVEY STREET EVERETT MA02149 TEL 617 387 4100 TELEX 94 9414 6 9 FAX 617 387 4456 OUTSIDE MA 800 227 2659 ...

Page 33: ...air or replacement See Figure 6 3 on page 6 11 6 8 DOOR ADJUSTMENT Table 6 3 Control Panel Assembly Parts List ITEM QTY DESCRIPTION PART NO I 1 Buzzer El 0 6682 2 1 Clean Generator Indicator Light round neon red E08 6530 3 1 Constant Steam Button E08 6526 4 1 Constant Steam Indicator Light round neon green E08 6529 5 1 Control Panel Housing Assembly E91 5743 6 1 Control Panel Light Mounting Bracke...

Page 34: ...6 Maintenance Figure 6 3 Control Panel Assembly MARKET FORGE INDUSTRIES INC 35 GARVEY STREET EVERETT MA 02149 TEL 6173874100 TELEX 94 9414 6 11 FAX 6173874456 OUTSIDE MA 800 227 2659 ...

Page 35: ...ont of the door by making sure that the striker in the door is centered with the latch mechanism on the front of the unit 7 Square the door to the unit by raising or lowering the hinge side of the door keeping the latch centered with the striker 8 Visually inspect the door Be sure that the door is square to the unit the striker is centered with the latch and the gasket is in contact with the entir...

Page 36: ...c plated E08 3841 The cooking compartment door handle tension is preset at the factory during assembly and should not need adjustment Should the door handle tension need adjustment the procedure is as follows Procedure I Open the cooking compartment door 2 Remove the 6 screws 3 from the top edge and 3 from the bottom edge of the door 3 Remove the door gasket door gasket mounting plate and door ins...

Page 37: ...6 Maintenance Figure 6 5 Cooking Compartment Door Assembly MARKET FORGE INDUSTRIES INC 35 GARVEY STREET EVERETT MA02149 6 14 TEL 61 7 387 4100 TELEX 94 94 I A FAX 6173874456 OUTSIDE MA 800 227 2659 ...

Page 38: ...crew 3 4 long stainless steel E10 1765 19 4 10 32 Nut with nylon insert zinc plated E08 3841 The cooking compartment door gaskets are made of a silicone type rubber material which is very durable but is subject to wear during normal daily operation This gasket may start to leak which will cause the steamer to malfunction Should the gasket begin to leak it should be replaced Procedure 1 Open the co...

Page 39: ...ntenance Figure 6 6 Upper Front Gas Powered Steam Generator Assembly MARKET FORGE INDUSTRIES INC 35 GARVEYSTREET EVERETT MA02149 TEL 617 387 4100 TELEX 94 94 1 A 6 16 FAX 617 387 4456 OUTSIDE MA800 227 2659 ...

Page 40: ...rass E91 5866 9 1 Main Burner Spud orifice brass Natural Gas E91 5867 9A 1 Main Burner Spud orifice brass LP Gas E91 5907 10 1 Silicone Insulator Boot E10 8333 11 1 Spray Nozzle E08 5017 12 1 Thermostat N O 193 F E10 8105 13 1 Warm up Burner E91 5884 14 2 Water Level Probe E08 6338 15 6 1 4 20 Nut with nylon insert stainless steel E08 3850 16 6 1 4 Flat Washer stainless steel E08 4011 17 1 8 32 Sl...

Page 41: ...enance Figure 6 7 Lower Back Gas Powered Steam Generator Assembly MARKET FORGE INDUSTRIES INC 35 GARVEY STREET EVERETT MA02149 6 18 TEL 6 1 7 387 4 1 00 TELEX 94 941 4 FAX 617 387 4456 OUTSIDE MA 800 227 2659 ...

Page 42: ...brass Natural Gas E91 5867 9A 1 Main Burner Spud orifice brass LP Gas E91 5907 10 1 Silicone Insulator Boot E10 8353 11 1 Spray Nozzle E08 5017 12 1 Thermostat N O 193 F E10 8105 13 1 Warm up Burner E91 5884 14 1 Water Level Probe low level sensor E08 6338 15 1 Water Level Probe long with bend high level sensor E91 5885 16 6 1 4 20 Nut with nylon insert stainless steel E08 3850 17 6 1 4 Flat Washe...

Page 43: ...6 Maintenance Figure 6 8 Steam Generator Gas Exhaust Duct Assembly MARKET FORGE INDUSTRIES INC 35 GARVEY STREET EVERETT MA 02149 6 20 TEL 617387 4100 TELEX 94 9414 FAX 6173874456 OUTSIDE MA 800 227 2659 ...

Page 44: ...3485 10 2 1 4 20 Hex head Machine Screw zinc plated 1 2 long E08 3490 11 2 1 4 20 Slotted Truss head Machine Screw Stainless steel 1 2 long E08 3489 12 2 1 4 Flat Washer zinc plated E10 2400 Figure 6 9 Blower Box Assembly Table 6 9 Blower Box Assembly Parts List ITEM QTY DESCRIPTION PART NO I 1 Blower E08 7501 2 1 Blower Box E91 5737 3 Blower Mounting Flange E08 7501 4 1 Blower Mounting Plate E91 ...

Page 45: ...ble 6 10 Tempering Tank Assembly Parts List ITEM QTY DESCRIPTION PART NO 1 3 Adapter Fitting 1 2 mNPTto 3 4 Hose Barb Brass E08 5029 2 4 Branch Tee 1 8 m NPT to 1 4 Hose Barbs Brass E08 5009 3 2 Cross Fitting Ml NPT Brass E08 5011 4 3 Drain Valve N O note orientation when installing E08 5021 5 1 Elbow Union 1 2 NPT Brass E09 4844 6 5 Eibow 1 4 mNPT to 1 4 Hose Barb Brass E08 5005 7 I Elbow 1 8 mNP...

Page 46: ...6 Maintenance Figure 6 10 Tempering Tank Assembly MARKET FORGE INDUSTRIES INC 35 GARVEY STREET EVERETT MA 02149 TEL 6 17 387 41 00 TELEX 94 9414 FAX 6 1 7 387 6 23 4456 OUTSIDE MA 800 227 2659 ...

Page 47: ...6 Maintenance Figure 6 1 I Gas Tubing Pipes Valves and Hardware MARKET FORGE INDUSTRIES INC 35 GARVEY STREET EVERETT MA02149 6 24 TEL 6173B74100 TELEX 94 9414 FAX 6173874456 OUTSIDE MA800 227 2659 ...

Page 48: ...lose Nipple cast iron E10 2810 9 2 1 2 NPT Elbow 90 cast iron E10 2811 10 1 1 2 NPT Nipple 1 3 4 long cast iron E08 5050 11 1 1 2 NPT Nipple 2 1 2 long cast iron E08 5051 12 1 1 2 NPT Nipple 4 long cast iron E08 5052 13 2 1 2 NPT Union cast iron E 10 3332 14 3 1 4 x 1 8 NPT Male Union Compression Fitting Assembly E08 5056 15 1 1 4 x 1 8 NPT Male Union Elbow Compression Fitting Assembly E08 5057 16...

Page 49: ...6 Maintenance Figure 6 12 Chassis Assembly MARKET FORGE INDUSTRIES INC 35 GARVEY STREET EVERETT MA02 I 49 6 26 TEL 6173874100 TELEX 94 9414 FAX 6 17 387 4456 OUTSIDE MA800 227 2659 ...

Page 50: ...d Machine Screw 1 1 4 long zinc plated E08 3497 13 4 4 40 Nyloc Hex Nut zinc plated E08 3845 14 4 4 Flat Washer zinc plated E10 1747 15 4 8 32 Hex Nut zinc plated E08 3840 16 6 8 Split Washer zinc plated E08 4009 17 4 8 Flat Washer zinc plated E08 4008 18 4 10 32 Slotted Truss Head Machine Screw 1 2 long zinc plated E08 3486 IMPORTANT Note the individual locations of each pressure switch See Figur...

Page 51: ...left pressure switch 6 5 E08 5019 15 1 T fitting to top compartment right pressure switch 10 E08 5019 PVC tubing clear 1 2 I D 1 8 wall damp all connections except at V fitting 16 1 tempering tank to Y fitting 5 E08 5024 17 1 Y fitting to top drip trough 29 E08 5024 18 1 Y fitting to bottom drip trough 7 5 E08 5024 Clamps 19 13 1 hose clamps Norprene and PVC connections as stated above E08 5014 20...

Page 52: ...6 Maintenance Figure 6 13 Tubing Routing MARKET FORGE INDUSTRIES INC 35 GARVEY STREET EVERETT MA 02149 6 29 TEL 6173874100 TELEX 94 941 4 FAX 6173874456 OUTSIDE MA 800 227 2659 ...

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