GAS OPERATED BOILER INSTALLATION, OPERATING, MAINTENANCE & PARTS MANUAL MODELS: • M24G100A-4SP • M24G200A-4SP • M36G100A-4SP • M36G200A-4SP • M36G300A-4SP WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.
TABLE OF CONTENTS INTRODUCTION ........................................................................................................................................ii TO THE KITCHEN MANAGER ..........................................................................................................ii INTRODUCTION . ..............................................................................................................................ii HOW TO USE THIS MANUAL ..........................................
INTRODUCTION TO THE KITCHEN MANAGER: 1. Read this manual carefully and in its entirety. Contact Market Forge Ind., Inc. for clarification if necessary. 2. Protect your kitchen personnel from scalding and other serious injury by providing training programs to acquaint all equipment operators with the correct and safe methods of operation. 3. Operators must be made aware of the consequences of misuse. Steam producing equipment, no matter who the manufacturer, is inherently dangerous when misused.
INSTALLATION INSTRUCTIONS GAS OPERATED BOILERS MODELS: • M24G100A - 4SP • M24G200A - 4SP • M36G100A - 4SP • M36G200A - 4SP • M36G300A - 4SP CAUTION: BE SURE TO READ: ► Keep this appliance area free and clear from combustibles. ► Do not obstruct the flow of combustion and ventilation air. ► Keep this manual for future reference. ► This installation must conform with local codes, or in the absence of local codes, with the National Fuel Gas code, ANSI Z223.1-Latest Edition.
INSTALLATION INSTRUCTIONS *GAS SERVICE CONNECTIONS: a) The boiler is factory adjusted for a gas input of 100, 200 & 300K BTU/HR at the pressure indicated. Please read the rating plate behind the Lift-Off Front Panel. If this plate is marked for a different gas than that supplied, notify your dealer immediately. Install an external gas supply shut off valve in a visible and accessible location.
INSTALLATION INSTRUCTIONS SERVICE CONNECTIONS: Gas Operated Boilers G GasConnection - 3/4” (19mm) IPS (100 & 200K BTU) G1 Gas Connection - 1” (25mm) IPS (275 & 300K BTU) CW1 Cold Water - 3/8” (10mm) O.D. tubing for cold water to boiler. Cold water lines will have a max of 50PSI (3.5 kg/cm2) and a min of 25PSI (1.8 kgcm2) water pressure. CAUTION: FILTER SYSTEM INSTALLATION INSTRUCTIONS MUST BE ADHERED TO WHEN CONNECTING A FILTER TO THIS LINE. CW2 Cold Water - 3/8” (10mm) O.D.
INSTALLATION INSTRUCTIONS LOWER DEFLECTOR ASSEMBLY 4
OPERATING INSTRUCTIONS MODELS: • M24G100A - 4SP • M24G200A - 4SP • M36G100A - 4SP • M36G200A - 4SP • M36G300A - 4SP Control Panel OPERATING INSTRUCTIONS STEAM GENERATORS FIRST CHECK TO BE SURE THAT: A. WATER SWITCH IS IN THE OFF POSITION. B. WATER SUPPLY VALVE IS OPEN. C. ELECTRICITY IS CONNECTED TO ALL UNITS. D. THAT THE GAS IS TURNED ON. (GAS OPERATED UNITS ONLY) E. THEN PROCEED WITH DAILY OPERATING PROCEDURES.
OPERATING INSTRUCTIONS CAUTION: BE SURE TO READ: ► Disconnect The Power Supply to the boiler before servicing or cleaning. ► Keep the appliance area free and clear of combustibles. ► Do not obstruct the flow of combustion and ventilation air. ► Keep this manual for future reference. ► Contact the factory, the factory representative, or an authorized service company to perform maintenance and repairs. ► In the event of a power failure, no attempt should be made to operate the appliance.
ADJUSTMENTS SETTING THE BOILER CONTROL PRESSURE SWITCHES: PRESSURE CONTROL SWITCH ADJUSTMENT: 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 operating level - 7 PSI (1kg/cm²). 2. Check boiler pressure gauge. If gauge indicates 5 to 7 PSI, pressure control switches are properly adjusted. 3.
GENERAL TROUBL-SHOOTING TROUBLE Pilot will not ignite or does not hold. POSSIBLE CAUSE 1. Gas not reaching unit. 2. Main “gas cock knob” not in ON position. 3. Air pocket or clog in gas line. 4. Defective wiring or poor connection at pilotstat power unit. Water enters boiler very slowly. Boiler overfills with water Main Burners will not ignite or will not remain lighted. REMEDY 1. Check to make sure gas is on and gas line is purged of air. 2.
GENERAL TROUBL-SHOOTING TROUBLE Boiler fails to reach full operating pressure of 5 lbs. or 15 lbs. POSSIBLE CAUSE 1. Pressure gauge reads inaccurately. 2. Pressure control and high limit control switches are out of adjustment. 3. Safety valve not seating properly. 4. Water level too high. 5. Air vent not venting properly. 6. Insufficient flames on burners or improper gas supply. Boiler fails to cut off after reaching operating pressure. 1. Pressure switch set too high or defective. 2.
TESTING PROCEDURE WATER CONTROL BOARD TESTING PROCEDURE This test procedure is to be used to determine if the control 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 properly after completing the testing. Tools Needed: » Digital or Analog V-O-M meter.
ILLUSTRATED PARTS LIST 24"24”Boiler CabinetShown Shown BoilerBase Base Cabinet ITEM NO. PART NO.
ILLUSTRATED PARTS LIST Pressure Switch Box Pressure Switch Box, without Cover ITEM NO. PART NO.
ILLUSTRATED PARTS LIST 11 Control Box Assembly, with and without Cover ITEM NO. PART NO.
ILLUSTRATED PARTS LIST 15 Plumbing, Left Side Gas Boiler, 24” ITEM NO. PART NO.
ILLUSTRATED PARTS LIST 13 Front View Gas Boiler, 24", 200K Front View Gas Boiler, 24”, 200K ITEM NO. PART NO.
ILLUSTRATED PARTS LIST 200K BTU Boiler Gas Train, 200K BTU Shown Boiler Shown ITEM NO. PART NO.
ILLUSTRATED PARTS LIST 200K BTU Boiler Shown Gas Train, 200K Boiler Shown ITEM NO. PART NO. DESCRIPTION 1 08-7832 Tube, Flex, Gas Line 2 10-1154 Compression Coupling 3 98-3890 Pilot Tube 4 94-5099 Spark Pilot and Igniter 5 94-5129 Pilot Orifice, Prop.
ELECTRICAL INFORMATION Wiring Diagram for New Generation Boilers - 100K, 200K and 300K BTU D 98 - 1129 F 18
ELECTRICAL INFORMATION Schematic Diagram for New Generation Boilers - 100K, 200K and 300K BTU D 98 - 1129 F 19
MAINTENANCE CLEANING THE BOILER: Market Forge recommends that the boiler be cleaned periodically due to impurities introduced through the water supply. All water supplies contain some mineral deposits and impurities, the degree varies with geographic location. Market Forge is recommending a cleaning schedule that will keep your equipment in proper, safe working order where water supplies are relatively pure.
MAINTENANCE 3. Clean rust, scale and lime deposits from the inside of the boiler with a wire brush. DO NOT DAMAGE COPPER HEATING ELEMENTS - BRUSH LIGHTLY. WORK DEPOSITS TO REAR CORNER AND REMOVE WITH PUTTY KNIFE. 4. After removing all debris, flush out with clean water through the hand-hole and drain . 5. Clean the hand-hole cover with a wire brush and wash. Be sure the areas that contact the gasket and dynaseal are clean and smooth. Fig. 2. Fig. 3. 6.
APPLICATION INSTRUCTIONS S-2299 APPLICATION INSTRUCTIONS FOR TOTAL CONCEPT CLEANING OF BOILER SIZE: 1 Gallon PART NUMBER: 20 - 0307 GENERAL NOTES: Market Forge R has two basic types of boilers; one has an automatic drain valve, the other has a manual drain valve. To determine which type you have, open cabinet doors and you will see a control box with two switches and an indicator light. The instruction label on the control box will identify the boiler as being either automatic or manual.
APPLICATION INSTRUCTIONS S-2299 APPLICATION INSTRUCTIONS FOR TOTAL CONCEPT CLEANING OF BOILER SIZE: 1 Gallon PART NUMBER: 20 - 0307 Fig. 5 Fig. 8 4. Remove the shipping cap, replace it with the pouring cap. Cut the tip of the pouring cap at the first notch to a 45o angle. 8. Feed the tubing through the access port in the boiler compartment. NOTE: A minimum of 12” must be inserted. 5. Install the tubing firmly over the tip of the pouring cap. Fig. 9 Fig. 6 9.