FTM-L ERIE INGLE OR TWIN DIRECT TEAM MIXER KETTLE COMPLETE WITH HYDRAULIC POWER TILT BRIDGE INTALLATION - OPERATION - MAINTENANCE INGLE MODEL FTM-40L FTM-60L FTM-80L FTM-100L TWIN MODEL FTM-(2)40L FTM-(2)60L FTM-(2)80L FTM-(2)100L Telephone: (802) 658-6600 Fax: (802) 864-0183 www.marketforge.com PN 14-0375 Rev B (2/16) 2016 - Market Forge
Your ervice Agency s Address: Model erial number Oven installed by Installation checked by
IMPORTANT WARNING: Improper installation, adjustment, alternation, service or maintenance can cause property damage, injury or death. Read the installation, operation and maintenance instructions thoroughly before installing or servicing this equipment. FOR YOUR AFETY Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. TABLE OF CONTENT INTALLATION Introduction... 2 ervice Connections... 3 ervice Connections... 4 Installation Instructions... 5 OPERATION Operating Procedure... 6 MAINTENANCE Cleaning... 7 The information contained in this manual is important for the proper installation, use, and maintenance of this oven. Adherence to these procedures and instructions will result in satisfactory baking results and long, trouble free service. Please read this manual carefully and retain it for future reference. ERROR: Descriptive, typographic or pictorial errors are subject to correction. pecifications are subject to change without notice.
Introduction DECRIPTION: All Market Forge direct connected steam jacketed kettles pertaining to this manual are direct steam operated pressure vessels of a double wall stainless steel construction forming a steam chamber (jacket) enveloping the lower two-thirds of the kettle bowl surface. These kettles operate at a maximum of 35 PI. Construction shall be welded stainless steel type 304 satin finish. A doublewall kettle interior shall form a steam jacket around the lower 2/3 of the kettle. The bottom of the kettle shall be of hemispheric design for maximum heat transfer. (316 stainless steel liner is standard on 40 gallon for high-acid content products). The mixer is a variable-speed unit powered by a 5 hp electric motor driving a hydraulic pump. Two agitators shall be included: a primary stainless steel scraper/ agitator, and a secondary high-speed mixer. Both agitators shall be removable for cleaning, and no tools will be required for removal. The console front to have the main power switch, mixer lift switch, and variable speed control. The tubular legs shall be constructed of stainless steel pipe fitted with four-hole adjustable flanged feet for securing to the floor. A sealed stainless steel tilt mechanism shall permit the kettle to tilt forward a full 90 for complete emptying. The tilt mechanism shall be selflocking for positive stop action. The bridge is constructed of 10-gauge stainless steel and contains two heavy-duty hydraulic motors to drive the agitators. The bridge shall be power tilt, and swing 140 out of the way for kettle tilting or cleaning. CAPACITIE: FTM-40L - one 40 gallon (152 liters) kettle FTM-60L - one 60 gallon (227 liters) kettle FTM-80L - one 80 gallon (303 liters) kettle FTM-100L - one 100 gallon (380 liters) kettle FTM-(2)40L - two 40 gallon (152 liters) kettles FTM-(2) 60L - two 60 gallon (227 liters) kettles FTM-(2) 80L - two 80 gallon (303 liters) kettles FTM-(2) 100L - two 100 gallon (380 liters) kettles OPERATION WILL BE BY: Direct steam at 15 to 35 PI (1.0 to 2.46 kg/cm 2 ). 1/3 BHP required. Over 35 PI (2.46 kg/cm 2 ), a pressure-reducing valve is required. tandard hydraulic power supplies are either of the following: 208 Volt, 3 Ph, 60 Hz 240 Volt, 3 Ph, 60 Hz INTALLATION 2
ervice Connections INGLE KETTLE ERVICE CONNECTION ELECTRICAL CHARACTERITIC * team upply - 3/4 (19mm) IP for incoming steam at 15-50 PI (1.0-3.5kg/cm2) VOLTAGE 208 (197-219) PHAE 3 AMP 14 HZ 60 Cold Water - 1/2 (13mm) O.D. tubing to fill faucet (optional). 240 (220-240) 3 14 60 CR Optional Condensate Return - 1/2 (13mm) IP condensate return from kettle may be connected to condensate return line. 480 (360-500) 3 7 60 EC Electrical Connection - Mixer motor 5 HP *Pressure reducing valve is required if incoming pressure exceeds 35 PI (2.46 kg/cm2). Pressure relief valve must be installed in the incoming steam line if not connected to a Market Forge gas or electric steam generator. Valve is supplied on request at no extra cost. NOTE: PVC and CPVC pipe are not acceptable materials for drains. DIMENION MODEL A B C D E F G FTM-40L 26 [660] 62 [1575] 45.5 [1156] 55 [1397] 75.63 [1921] 14.75 [375] 56 [1422] FTM-60L 29.5 [749] 65 [1651] 49 [1245] 58.5 [1486] 80 [2032] 19 [483] 58 [1473] FTM-80L 33 [838] 67.75 [1721] 49 [1245] 58.5 [1486] 80 [2032] 19 [483] 60 [1524] FTM-100L 37.13 [943] 70.5 [1791] 49 [1245] 58.5 [1486] 85 [2159] 19 [483] 62 [1575] B 5 [129] 2 [51] 8.625 [219] 2.25 [57] WO 4 [102] EC 6 [152] WI 30 [762] 11 [279] 10.25 [260] 10 [254] 14 [356] 8 [203] CR 38.25 [971] DIMENION ARE IN INCHE [MM] FLANGED FOOT DETAIL 4 EQUALLY PACED 7/16 [11mm] DIA. HOLE ON 3 [76mm] B.C. A 4 [102] MIN. E 20.50 [521] 9 [229] D C F CR EC G (APPROX.) Figure 1 3 INTALLATION
ervice Connections TWIN KETTLE ERVICE CONNECTION ELECTRICAL CHARACTERITIC * team upply - 3/4 (19mm) IP for incoming steam at 15-50 PI (1.0-3.5kg/cm2) VOLTAGE 208 (197-219) PHAE 3 AMP 14 HZ 60 Cold Water - 1/2 (13mm) O.D. tubing to fill faucet (optional). 240 (220-240) 3 14 60 CR Optional Condensate Return - 1/2 (13mm) IP condensate return from kettle may be connected to condensate return line. 480 (360-500) 3 7 60 EC Electrical Connection - Mixer motor 5 HP *Pressure reducing valve is required if incoming pressure exceeds 35 PI (2.46 kg/cm2). Pressure relief valve must be installed in the incoming steam line if not connected to a Market Forge gas or electric steam generator. Valve is supplied on request at no extra cost. NOTE: PVC and CPVC pipe are not acceptable materials for drains. DIMENION MODEL A B C D E F G FTM-(2)40L 26 [660] 102 [2591] 45.5 [1156] 55 [1397] 75.63 [1921] 14.75 [375] 56 [1422] FTM-(2)60L 29.5 [749] 108 [2743] 49 [1245] 58.5 [1486] 80 [2032] 19 [483] 58 [1473] FTM-(2)80L 33 [838] 116 [2996] 49 [1245] 58.5 [1486] 80 [2032] 19 [483] 60 [1524] FTM-(2)100L 35.5 [902] 121 [3073] 49 [1245] 58.5 [1486] 85 [2159] 19 [483] 63 [1600] B 8 [203] 4 [102] EC 8 [203] 8.625 [219] 10 [254] 2.25 [57] WO 6 [152] WI 10.25 [260] 11 [279] 30 [762] 38.25 [971] DIMENION ARE IN INCHE [MM] FLANGED FOOT DETAIL 4 EQUALLY PACED 7/16 [11mm] DIA. HOLE ON 3 [76mm] B.C. CR CR 4 [102] MIN. A 3.5 [89] E 2 [51] 7 [179] D C F EC CR 2 PL G (APPROX.) Figure 2 INTALLATION 4
Installation Instructions 1. elect a location to provide drainage for kettle pour path when tilted and for butterfly valve if so equipped. 2. Mark hole location on the floor through flange feet. Move kettle to drill holes. 3. At marked hole locations, drill holes and insert expansion shields to accommodate 5/16 size lag bolts. 4. Reposition kettle, level kettle by making necessary adjustments to adjustable flange feet. 5. Bolt down kettle and seal the flanged feet with a ilastic or other equivalent sealing compound. ealant must be applied no only to the bolt heads but also around the flanges making contact with the floor surface to fulfill NF requirements. 6. Connect steam line (3/4 pipe size) to the steam inlet, make sure there is a steam control valve strainer fairly conveniently placed near the kettle. 7. Connect kettle condensate return line to a drain or to a boiler return line. Each kettle lines must have a suitable steam trap. Boiler return lines must have a check valve. 8. afety relief valve on kettle must not be plugged as it is set to relieve excess pressure in the kettle. 9. If incoming steam pressure is greater than kettle maximum operating pressure then a pressure reducing valve must be installed in the line. 10. If large amounts of water accumulate in the steam line it will be necessary to install one or more ball float traps in the line to eliminate water. 11. A steam line pressure gauge is also recommended to determine the actual amount of steam coming to the kettle. 12. Make electrical connection for hydraulic console as per electrical data plate on the unit. WARNING When making electrical connection ensure that motor rotates in correct direction. pump may be damaged if incorrect. 13. Check for proper operation. 5 INTALLATION
Operating Procedure OPERATING PROCEDURE 1. If kettle has draw-off valve, close it. 2. Fill kettle with product to desired level. 3. lowly turn the steam control valve on to full open position (counterclockwise). 4. The water or food should boil 3-4 minutes per gallon. If it does not, then incoming pressure should be checked to determine that it is adequate to operate the kettle efficiently. 5. Regulate steam control valve depending on type of food being prepared. 6. When food is cooked, turn off steam, remove food and clean kettle immediately to prevent residue from drying on kettle bowl surface. OPERATING MIXER UNIT Power to operate the mixer unit is controlled by the main power switch located on the left side of the control panel. Place switch in on position. Ensure that mixer speed control is set to the stop position. et the mixer switch, located next to the main power switch to the on position. Note that the agitators should not be turning. The speed control has four basic settings which are, stop, slow, medium and fast. et the speed control to the slow position and observe the agitators will begin to turn. CAUTION NEVER PLACE HAND INIDE KETTLE WHEN THE AGITATOR ARE IN MOTION. Increasing the speed setting on the control will increase the speed at which the agitators turn. NOTE: Always start agitators at the slow speed and then gradually increase to the desired speed to avoid splashing or throwing the product over edge of kettle. Push the tilt switch to the raise position a nd hold. Bridge will raise to maximum height. Bridge will stop at any position the tilt switch is released and will remain until the switch is pushed to wither raise or lower. NOTE: The bridge is equipped with a safety which prevents turning of the agitators, regardless of the mixer switch, or speed control settings. Agitators will not engage unless the bridge is lowered so that the guide pin rests fully in the guide pin bracket on the side of the kettle. REMOVAL OF AGITATOR The agitators are removable without tools, for ease of cleaning. To remove raise bridge as described in Raising Mixer Bridge and swing clear of kettle. Grasp shaft of large agitator, push up and turn to disengage lock pin. Pull straight down on agitator. Remove the small agitator in the same manner. If it is necessary to remove scrapers blades for cleaning purposes, remove the pin at the end of the mounting shaft and then slide the scraper blade off the shaft. EXTREMELY LOW COOKING TIME: If the cooking time is abnormally slow then the difficulty may be due to insufficient steam pressure. First determine that pressure on incoming stream line at kettle is with in 15 PI of rated kettle pressure. Note that pressure approaching the rated kettle pressure are liable to set off the safety relief valve. If required pressure is available to kettle, then possibly volume of steam is not sufficient. Minimum 3/4 pipe size is required to the kettle but if the steam generating source is at a great distance from the kettle, larger pipe will be required. Finally, the core of the steam flow will require disassembly and inspection. RAIING MIXER BRIDGE Tilt kettle for emptying or to clean agitators, the mixer bridge will tilt hydraulically upward and manually swing to clear the kettle. To do this, first turn speed control to stop and then turn mixer switch to off. NOTE: Mixer agitator arms must be stopped at 90O to the mixer bridge before raising the bridge. If the agitator arms do not stop in this position when speed selector is set to stop, the jog the selector on and off to achieve this position. OPERATION 6
Cleaning & Preventative Maintenance DAILY CLEANING 1. Ensure that steam supply is off. 2. Pre-rinse inside of kettle thoroughly and drain to remove any food. 3. Using a nylon brush, clean kettle with a mild detergent and warm water rinse. Never use steel wool or scouring pads as it will scratch the stainless steel. 4. Tilt kettle fully to open the tangent draw-off valve if one is provided to allow soap and water solution to drain. Rinse with clean water. 5. On kettles equipped with a draw-off valve, by hand turn the large hex nut counterclockwise until ti is completely disengaged from thread. Grasp knob to valve and slowly pull out valve stem and disc. Do not allow disc to come in contact with hard surfaces since damage to disc may occur and result in valve leakage. Wash the valve stem, disc and handle. Insert nylon brush with detergent into interior of valve body and tangent draw-off tube and brush vigorously. Replace valve steam assembly and engage hex nut fully by hand. Flush kettle with clean warm water. Leave valve open when kettle is not in use. WARNING It is not recommended to use cleaning agents that are corrosive. Use of cleaning agents that contain chloride, acids or salts are corrosive and may cause pitting and corrosion when used over a period of time; this will reduce the life of the unit. hould pitting or corrosion occur this is not covered by warranty. Follow the recommended cleaning instructions. Use a mild detergent, warm water and rinse thoroughly. REERVOIR Maintain oil level at all times. The oil should be checked after the first 100 hours and verify that the class of oil meet the requirements of the pump being used. Change the oil every 1,000 to 2,000 hours depending on the application and operating environment. HYDRAULIC YTEM 1. et up regular schedule for checking the oil temperature, appearance, smell and feel. Change oil as recommended by the equipment manufacturer. 2. Be prompt about removing, checking and repairing or replacing valves, pumps or other components that are running hot. 3. Break in new components gradually. New, closefitting parts expand at different rates and are especially prone to seize when they get too hot. 4. tart a cold pump or motor on hot oil by jogging just enough to draw the hot oil into the component. Then wait a few minutes to allow the temperatures to equalize in all the pumps parts. Repeat until the temperature on the outside of the pump ios the same as that on the piping. 5. Keep your equipment clean. A thick layer of dirt acts as insulation. It will prevent the hydraulic system from extracting heat. 6. On hot days and in hot climates check and change the oil more frequently. Be sure to use an oil recommended for hot weather operation by the oil supplier. PREVENTATIVE MAINTENANCE FILTER Change or clean as required or as indicated on filters supplied with visual indicators. Filers must be maintained. The key to good filtration is filter maintenance. A machine may be equipped with the best filters available and they may be positioned in the systems when they do the most good; but, if the filters are not take care of and cleaned when dirty will be a waste of time and money. A filter which get dirty after one day of operation and if cleaned 29 day later gives you 29 days of non-filtered fluid. 7 MAINTENANCE