Market Forge Industries M24E Quick start guide

EFFECTIVE SEPTEMBER 2, 2014
M24E & M36E
ELECTRICALLY OPERATED BOILERS
PARTS AND SERVICE MANUAL
MARKET FORGE
Telephone: [phone] Fax: [phone]
www.marketforge.com
P/N 14-0310 Rev A (9/14)
Superseding All Previous Parts Lists.
The Company reserves the right to make substitution in the event that items specied are not available.
ERRORS: Descriptive and/or typographic errors are subject to correction.

SEPTEMBER 2, 2014 2 M24E & M36E ELECTRIC BOILERS
TABLE OF CONTENTS
GENERAL TROUBLESHOOTING .......................................................3
PRESSURE ADJUSTMENT.............................................................5
WATER CONTROL BOARD TESTING PROCEDURE .....................................6
WIRING DIAGRAMS
NEW GENERATION ELECTRIC BOILERS ...............................................8
18 KW, 24 KW ....................................................................... 10
36 KW, 42 KW, 48 KW ................................................................ 12
36 KW, 48 KW ....................................................................... 13
ILLUSTRATED PARTS LIST
24" BOILER BASE ................................................................... 14
PRESSURE SWITCH BOX, WITHOUT COVER......................................... 15
CONTROL BOX ASEMBLY, WITH & WITHOUT COVER ................................. 16
ELECTRIC BOILER, LEFT SIDE VIEW – 36” ........................................... 17
ELECTRIC BOILER, FRONT VIEW – 36”............................................... 18
ELECTRIC BOILER, CONTACTOR BOX ............................................... 19
ELECTRIC BOILER, ELEMENTS...................................................... 20

SEPTEMBER 2, 2014 3 M24E & M36E ELECTRIC BOILERS
GENERAL TROUBLESHOOTING
TROUBLE POSSIBLE CAUSE REMEDY
Water does not enter the boiler. Water main shut-off Turn on
Power not reaching unit Check main fuse or circuit
Probes dirty Remove and clean
Water level control board defective Refer to test procedure in this manual
Solenoid valve defective If 120V is veried at solenoid coil, but fails to
open, replace solenoid
Boiler fails to build up pressure
when water level is proper and
fuel switch is turned on.
Check to see that circuit breaker in main is
turned on
Check for voltage at terminal block
Check to see that contactors are pulling in Check continuity of coil, if open replace
Current ow is broken at water level control (as-
certain with continuity check)
Check for voltage at L1 and L2, replace if de-
fective
Current ow is broken at pressure control or
high limit control switches due to maladjustment
or defect (ascertain with continuity check)
Readjust - to proper setting - refer to instruc-
tions for readjustment, replace if defective
Heating elements are defective Replace if continuity check through the circuit of
each element shows defective
Boiler fails to reach full operating
pressure of 5 lbs. or 15 lbs.
Pressure gauge reads inaccurately Replace
Pressure control and high limit control switches
are out of adjustment
Follow instructions for readjusting or replace if
defective
Safety valve not seating properly Clean or replace
Contactor coils (one or both) not energizing and
closing circuit to the heating elements
Check - replace either contactor coils or com-
plete contactor – if found defective. Measure
amperage at terminal block check to be sure
there is an even draw on all three phases - see
wiring diagrams for correct AMP draw. If uneven
or zero amperage draw is found on one of the
three phases, check for blown fuse. If fuse is
OK, shut off power, remove wires from heating
elements and run continuity check - replace if
defective.
Water enters boiler very slowly. Dirty Strainer screen in solenoid valve. Clean or replace strainer screen, part no. 08-
4871.
Water level in gauge glass uctu-
ates up and down.
Top shut off on water gauge is closed. Open
Contactor chatters Incorrect supply voltage. Check to see that it matches it with coil contac-
tors
Dirty or worn contactor points. Clean or replace contactor
Weak coil Replace with correct voltage coil
15 lbs. safety valve blows off pre-
maturely
Pressure set too high Readjust
Pressure gauge reads incorrectly Replace
Mineral build-up or dirt on seat of valve Clean
Weak spring valve Replace valve
Boiler build up to pressure, shuts
down and fails to come on
High limit switch set too low or operating pres-
sure control switch set too high
Follow instructions in this document for read-
justing, or replace if defective

SEPTEMBER 2, 2014 4 M24E & M36E ELECTRIC BOILERS
GENERAL TROUBLESHOOTING
TROUBLE POSSIBLE CAUSE REMEDY
Air vent leaking Not closing Replace
Cold water condenser does not
function
Main water line shut off Turn on
Thermostat defective Replace if defective
Tighten coil nut Tighten coil nut
Check solenoid coil for continuity, if open re-
place
Check coil for continuity, if open replace
Product in cooker does not cook
properly on rst cycle, but cooks
alright after rst cycle is exhaust-
ed
Air vent is closing Replace
Contactor chatters Low voltage Check voltage condition. Check momentary
voltage dip during starting. Low voltage pre-
vents magnet sealing. Check coil voltage rating
Defective or incorrect coil Replace coil, rating of coil must match the line
voltage
Welding or freezing Abnormal spike in current Check for grounds or shorts in system
Low voltage preventing magnet from sealing Correct voltage condition
Short circuit Remove short fault and check to be sure fuse or
breaker size is correct
Short contact button life and / or
overheating of contacts
Filling or dressing Do not le silver tips. Rough spots or discolor-
ation will not harm tips or impair their efciency
Interrupting excessively high current Check for grounds, shorts or excessive current
Discolored contacts caused by insufcient con-
tact pressure, loose connection, etc.
Check contact carrier for deformation or dam-
age, clean and tighten connections
Dirt or foreign matter on contact surface Clean with Acetone
Short circuit Remove fault and check to be sure fuse or
breaker size is correct
Open circuit Mechanical damage Handle and store carefully. Do not handle coils
by the leads
Burnt-out coil due to overvoltage or defect Replace coil
Overheated Coil Over-voltage or high ambient temperature Check application and circuit
Wrong coil Check rating (voltage and frequency) if incor-
rect, replace with proper coil
Shorted turns caused Replace coil
Under voltage, failure of magnet to seal in Correct system voltage. Install new coil

SEPTEMBER 2, 2014 5 M24E & M36E ELECTRIC BOILERS
If boiler fails to maintain steam pressure in operating
range, pressure control switch may require adjustment.
1. Start boiler and allow pressure to build up to operat-
ing level - 15 PSI (1kg/cm²).
2. Check boiler pressure gauge. If gauge indicates 12
to 14 PSI, pressure control switches are properly ad-
justed.
3. If boiler does not come on when pressure gauge
reads 7 PSI and does not go off when pressure gauge
reads 14 PSI, proceed as follows:
Pressure Switch Adjustment
WARNING
Because power must be on to adjust pressure
switches, be sure to protect against electrical
shock.
1. Remove screw and lift front cover off control box.
2. Hand adjust operating pressure control switch and
high limit pressure control switch by turning adjust-
ing nut (Knurled knob) clockwise to raise and coun-
ter clockwise to lower actuation point. Switch should
be set so that boiler comes on when boiler pressure
gauge reads 12 PSI and goes off when gauge reads
14 PSI. Hi limit switch should be set so that boiler will
shut off if pressure reaches 15 PSI.
3. The actuation value (differential) is factory set and
cannot be changed.
4. The cold water condenser thermostat is preset at fac-
tory.
5. Repeat steps, 1, 2, and 3. If 12 to 14 PSI boiler pres-
sure gauge reading is obtained during boiler opera-
tion, adjustment is correct. If proper adjustment can-
not be made consult Trouble-Shooting Guide in this
manual.
6. After making adjustments, replace cover on pressure
switch box and screw.
PRESSURE ADJUSTMENT
OPERATING SWITCH
HI LIMIT SWITCH

SEPTEMBER 2, 2014 6 M24E & M36E ELECTRIC BOILERS
WATER CONTROL BOARD TESTING PROCEDURE
LED 1
LED 2
LED 3
RESET
LW2
GND
LW1
FW - HIGH
HTA NO
LO LITE (NC)
FW (NO)
L1
L2
This test procedure is to be used to determine if the con-
trol is working properly. It is not intended to determine why
the control may have failed.
If testing shows that the control is operating properly,
check all probe and solenoid wiring and the condition of
the electrodes in the steam chamber.
Contact the factory if the boiler still does not operate prop-
erly after completing the testing.
Tools Needed:
• Digital or Analog V-O-M meter.
• Alligator clip type test jumpers (2 sets min.).
Turn Off Power to Control:
• Use V-O-M to verify there is no power at terminals L
1 & L2.
• Use V-O-M to verify that there is no power at termi-
nals ‘FW(NO)’, ‘LO LlTE(NC)’ & ‘HTR(NO)’. If there
is power at any of these terminals, you will need to
nd the source and turn it off.
Remove Wires from Probe and Relay Switch Termi-
nals:
• DO NOT remove wires from L 1 & L2 terminals.
• Tag wires and remove from probe and relay contact
terminals including ‘GND’ terminal.
• Tag and remove wires from ‘RESET’ terminals.
• Connect jumper wire to both ’RESET’ terminals.
Turn Power On to Terminals L 1 & L2:
• ‘LED l’ should turn on.
• ‘LED 2’ should be off.
• ‘LED 3’ should be off.
• Use V-O-M to verify that there is power at ‘FW(NO)’
& ‘LO LlTE(NC)’ terminals and no power ‘HTR(NO)’
terminals
Test Feedwater Function:
• Connect jumper wire to ‘FW HIGH and ‘GND’ termi-
nals.
• ‘LED l’ should turn off after a 10 second delay.
• Use V-O-M to verify that there is no power at the
‘FW (NO)’ terminal.
• Remove jumper from ‘FW HIGH’ and ‘GND’ termi-
nals. . ‘LED l’ should turn on.
• Use V-O-M to verify that there is power at the
‘FW(NO)’ terminal.

SEPTEMBER 2, 2014 7 M24E & M36E ELECTRIC BOILERS
WATER CONTROL BOARD TESTING PROCEDURE
Test Primary Low Water Function:
• Connect jumper wire to ‘LW(1) and‘GND’ terminals.
• ‘LED 2’ should turn on.
• Remove jumper wire from ‘LW(1)’ and ‘GND’ termi-
nals.
• ‘LED 2’ should turn off after a 3 second delay.
• Connect jumper wire to ‘LW(1)’ and ‘GND’ terminals.
• ‘LED 2’ should turn on.
IMPORTANT
Jumper wire between ‘LW(1) and ‘GND’ termi-
nals must remain in place to test secondary
low water function.
Test Secondary Low Water Function:
• Connect jumper wire to ‘LW(2)’ and ‘GND’ terminals.
• ‘LED 3’ should remain off.
• Use V-O-M to verify that there is power at the ‘LO
LlTE(NC)’terminal and no power at the ‘HTR(NO)’
terminal.
• Remove the jumper wires from the ‘RESET’ termi-
nals.
• ‘LED 3’ should turn on.
• Use V-O-M to verify that there is no power at the
‘LO LlTE(NC)’ terminal and power at the ‘HTR(NO)’
terminal.
• Connect jumper wire to ‘RESET’ terminals.
• Remove jumper wire from ‘LW(2)’ and ‘GND’ termi-
nals.
• ‘LED 3’ should turn off after a 3 second delay.
• USE V-O-M to verify that there is power at the ‘LO
LlTE(NC)’ terminal and no power at the ‘HTR(NO)’
terminal.
• Connect jumper wire from ‘LW(2)’ and ‘GND’ termi-
nals.
• ‘LED 3’ should remain off.
IF ANY OF THE FUNCTIONS DO NOT WORK, RE-
PLACE THE BOARD!
IF ALL FUNCTIONS WORK, TROUBLE-SHOOTING
OTHER COMPONENTS WILL BE REQUIRED!

SEPTEMBER 2, 2014 8 M24E & M36E ELECTRIC BOILERS
NEW GENERATION ELECTRIC BOILERS
WIRING DIAGRAM
D94 - 5045
C

SEPTEMBER 2, 2014 9 M24E & M36E ELECTRIC BOILERS
NEW GENERATION ELECTRIC BOILERS
SCHEMATIC DIAGRAM
D94 - 5045
C

SEPTEMBER 2, 2014 10 M24E & M36E ELECTRIC BOILERS
18 KW, 24 KW
WIRING

SEPTEMBER 2, 2014 11 M24E & M36E ELECTRIC BOILERS
18 KW, 24 KW
WIRING

SEPTEMBER 2, 2014 12 M24E & M36E ELECTRIC BOILERS
36 KW, 42 KW, 48 KW
WIRING

SEPTEMBER 2, 2014 13 M24E & M36E ELECTRIC BOILERS
36 KW, 48 KW
WIRING

SEPTEMBER 2, 2014 14 M24E & M36E ELECTRIC BOILERS
24" BOILER BASE
1
3
4
8
2
9
7
5 65
ITEM PART NO. DESCRIPTION
108-5894 Market Forge Nameplate Log
291-5795 Handle, Front
3 98-3992 Panel, Front Assy, 24”
98-3993 Panel, Front Assy, 36”
410-0631 Leg, 6”
08-5211 Leg, 10”
08-5208 Leg, Flanged 6”
08-5206 Leg, 8”
10-0326 Caster, 5”
5 98-3968 Trim, Edge
698-3978 Glass
798-3991 Gasket, Adhesive
898-3994 Panel, Side Assy
998-3995 Panel, Rear Assy, 24”
98-3996 Panel, Rear Assy, 36”

SEPTEMBER 2, 2014 15 M24E & M36E ELECTRIC BOILERS
PRESSURE SWITCH BOX, WITHOUT COVER
ITEM PART NO. DESCRIPTION
1 94-5064 Box, Pressure Switch
210-8410 Pressure Switch, Hi-Limit
310-8411 Pressure Switch, Operating
498-3875 Switch, Drain By-Pass
508-7933 Manifold, Pressure Switches
610-4804 Pressure Gauge

SEPTEMBER 2, 2014 16 M24E & M36E ELECTRIC BOILERS
CONTROL BOX ASEMBLY, WITH & WITHOUT COVER
ITEM PART NO. DESCRIPTION
108-6549 Switch, Power
294-5127 Switch, Manual Reset
310-5052 Light, Red
494-5003 Control Box Lexan
508-6469 Fuse Holder
698-1680 Board, Water Level Control
708-6472 Relay Tube
808-6475 Relay Base
998-3877 Relay Bracket
10 08-6468 Fuse, 5A

SEPTEMBER 2, 2014 17 M24E & M36E ELECTRIC BOILERS
ELECTRIC BOILER, LEFT SIDE VIEW – 36”
ITEM PART NO. DESCRIPTION
110-0239 Hose, Drain
210-4137 Clamp, Hose
391-6927 Box, Drain Assy.
4 10-5234 Transformer
510-1058 Valve, Cold Water Condenser, 120V
6 08-4822 Valve, Boiler Feed
7 08-7959 Hose, Condense
898-3894 Copper Nozzle
998-1401 Valve, Check
10 10-0287 Hose, Drain
11 10-4137 Clamp, Hose
12 08-7974 Clamp Hose
13 98-3914 Compression Fitting
14 10-4556 Air Vent
15 08-4900 Manual Valve, Water Inlet
16 98-3892 Thermostat, Cold Water Condenser

SEPTEMBER 2, 2014 18 M24E & M36E ELECTRIC BOILERS
ELECTRIC BOILER, FRONT VIEW – 36”
ITEM PART NO. DESCRIPTION
110-1311 Valve, Drain, 120V
210-5320 Valve, Safety, 15PSI
398-1667 Cover, Front, Contactor Box
494-5065 Cover, Pressure Switch Box
508-5447 3/4” NPT, Brass Street Elbow
610-2728 Water Gauge Glass Assembly
6a 10-4754 Water Gauge (Glass Only)
708-7933 Pressure Switch Manifold
808-5427 3/4” Br. Nipple, 2 1/2” Lg.
908-4991 3/4” Side Outlet Tee
10 10-7943 3/4” Brass Union
11 10-1126 3/4” Nipple, 2” Brass
12 10-3455 90O Elbow
Not Shown 98-1656 Cover, Rear, Contactor Box

SEPTEMBER 2, 2014 19 M24E & M36E ELECTRIC BOILERS
ELECTRIC BOILER, CONTACTOR BOX
ITEM PART NO. DESCRIPTION
198-1670 Box, Contactor
210-5944 Contactor
398-1720 Terminal Block
408-6553 Hi-Limit Thermostat
510-5220 Ground Lug
608-7981 Terminal Strip
798-1663 Bracket, Contactor Mounting
898-4014 Bracket, Contactor Tray

SEPTEMBER 2, 2014 20 M24E & M36E ELECTRIC BOILERS
ITEM PART NO. DESCRIPTION
198-1659 Plate, Front
298-1673 Gasket, Front Plate
391-8660 Gasket, Htg. Element
4A 08-6485 Heating Element, 9kW, 208 Volts
4B 08-6486 Heating Element, 9kW, 240 Volts
4C 08-6487 Heating Element, 9kW, 480 Volts (a.k.a 277 Volts)
4D 08-6415 Heating Element, 12kW, 208 Volts
4E 08-6416 Heating Element, 12kW, 240 Volts
4F 08-6417 Heating Element, 12kW, 480 Volts (a.k.a 277 Volts)
4G 08-6491 Heating Element, 14kW, 208 Volts
4H 08-6418 Heating Element, 16kW, 208 Volts
4J 08-6419 Heating Element, 16kW, 240 Volts
4K 08-6420 Heating Element, 16kW, 480 Volts (a.k.a 277 Volts)
508-6337 Water Level Probe
6A 98-3936 Screw, 1/4-20 Socket Set Screw, Stainless Steel
6B 08-7840 Nut, 1/4-20 Flanged
ELECTRIC BOILER, ELEMENTS