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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.
FOR YOUR SAFETY:
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND
LIQUIDS IN THE VICIN
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TABLE OF CONTENTS INTRODUCTION .......................................................................................................................................ii TO THE KITCHEN MANAGER .........................................................................................................ii INTRODUCTION ...............................................................................................................................ii HOW TO USE THIS MANUAL ...........................
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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 ac- quaint 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 misuse
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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. For installation i
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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. If the unit is placed at the minimum side clearances rather than the optimum side clearances, th
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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 2 of 50PSI (3.5 kg/cm ) and a min of 25PSI (1.8 2 kgcm ) water pressure. CAUTION: FILTER SYS- TEM INSTALLATION INSTRUCTIONS MUST BE ADHERED TO WHEN CONNECTING A FILTER TO THIS LINE. CW2 Cold Water - 3/8” (10mm) O.D. tubing
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INSTALLATION INSTRUCTIONS LOWER DEFLECTOR ASSEMBLY 4
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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. DAILY OPERATING PROCEDURE STEP 1 PRESS WATER
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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. Be sure
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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 ad- justed. 3. If boiler does not come on when pressure gauge reads 7 PSI and does not go off when pressur
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GENERAL TROUBL-SHOOTING TROUBLE POSSIBLE CAUSE REMEDY Pilot will not ignite or does not hold. 1. Gas not reaching unit. 1. Check to make sure gas is on and gas line is purged of air. 2. Main “gas cock knob” not in ON position. 2. Depress and turn “main gas cock” to pilot position - (refer to 3. Air pocket or clog in gas line. lighting instructions). 4. Defective wiring or poor con- 3. Purge or blow out gas line. nection at pilotstat power unit. 4. Check - replace or tighten. 5. Defective s
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GENERAL TROUBL-SHOOTING TROUBLE POSSIBLE CAUSE REMEDY Boiler fails to reach full operating 1. Pressure gauge reads inaccu- 1. Replace. pressure of 5 lbs. or 15 lbs. rately. 2. Follow instructions for readjust- 2. Pressure control and high limit ing. (page 10) control switches are out of ad- 3. Purge manually or replace. justment. 4. Adjust water level control 3. Safety valve not seating prop- - check water feed valve for erly. sticking - clean or replace. 4. Water level too high. 5. Replace. 5
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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 de- termine why the control may have failed. If testing shows that the control is operating properly, check all probe and solenoid wiring and the condi- tion of the electrodes in the steam chamber. Contact the factory if the boiler still does not operate properly after completing the testing. Tools Needed: » ‘LED l’ should turn off af
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ILLUSTRATED PARTS LIST 24" Boiler Base Cabinet Shown 24” Boiler Base Cabinet Shown ITEM NO. PART DESCRIPTION NO. 1 91-8892 Flue Outer, 24” Front 1 91-8938 Flue Outer, 36” Front 2 91-8893 Flue Outer, 24” Back 2 91-2713 Flue Outer, 36” Back 3 98-0593 Flue Inner Assy, 100 & 200k Boiler 3 91-8936 Flue Inner Assy, 300k Boiler 4 08-5894 Market Forge Nameplate Logo 5 91-5795 Handle, Front 6 94-5007 Panel, Front Assy, 24” 6 94-5006 Panel, Front Assy, 36” 7 10-0631 Leg, 6” 7 08-5206 Leg, 8” 7 08-5211
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ILLUSTRATED PARTS LIST Pressure Switch Box Pressure Switch Box, without Cover ITEM NO. PART DESCRIPTION NO. 1 94-5064 Box, Pressure Switch 2 10-8410 Pressure Switch, Hi-Limit 3 10-8411 Pressure Switch, Operating 4 98-3875 Switch, Drain By-Pass 5 08-7933 Manifold, Pressure Switches 6 10-4804 Pressure Gauge 12
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ILLUSTRATED PARTS LIST 11 Control Box Assembly, with and without Cover ITEM NO. PART DESCRIPTION NO. 1 08-6549 Switch, Power 2 94-5127 Switch, Manual Reset 3 10-5052 Light, Red 4 08-6450 Transformer, 120-240V 5 98-1680 Board, Water Level Control 6 94-5022 Ignition Module 7 08-6472 Relay Tube 8 08-6475 Relay Base 9 98-3877 Relay Bracket 10 94-5003 Artwork, Control Box 11 94-5066 Cover 12 94-5069 Terminal Strip 13
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ILLUSTRATED PARTS LIST 15 Plumbing, Left Side Gas Boiler, 24” ITEM NO. PART DESCRIPTION NO. 1 10-0239 Hose, Drain 2 10-4137 Clamp Hose 3 91-692 7 Box Drain Assy 4 10-7955 Valve, Safety, 15 PSI 5 10-1058 Valve, Cold Water Condenser, 120V 6 10-1311 Valve, Drain, 120V 7 08-4822 Valve, Boiler Feed 8 08-7959 Hose, Condenser 9 98-3894 Copper, Nozzle 10 98-3914 Comp Fitting 11 98-1401 Valve, Check 12 10-0287 Hose, Drain 13 10-4137 Clamp, Hose 14 08-7974 Clamp, Hose 15 98-3892 Condenser Thermostat 14
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ILLUSTRATED PARTS LIST 13 Front View Gas Boiler, 24", 200K Front View Gas Boiler, 24”, 200K ITEM NO. PART DESCRIPTION NO. 1 08-4900 Water Inlet, Manual Valve 2 94-5023 Gas Valve 3 94-5033 Gas Manifold, 100K & 200K Boilers 3 94-5034 Gas Manifold, 300K Boilers 4 10-3661 Drain Valve, Maunal 5 10-1311 Drain Valve, Automatic 6 91-5112 Probe Plate Assy 7 10-7955 Safety Valve 8 10-4556 Air Vent 9 08-4991 Tee, 3/4”, Side Outlet 10 94-5065 Cover, Pressure Switch Box 11 94-5010 Label, Pressure Switch Box
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ILLUSTRATED PARTS LIST 200K BTU Boiler Shown Gas Train, 200K BTU Boiler Shown ITEM NO. PART DESCRIPTION NO. 1 98-3923 Vent, Bleeder 2 10-7955 Valve, Safety, 15 PSI 3 91-7031 Probe Plate 4 08-4413 Gasket, Probe Plate 5 08-6399 Probe, Lowest Probe Kit; P/N: 91-5112 6 08-6398 Probe } 7 08-6364 Probe 8 91-8810 Cover Hand Hole 9 08-4415 Gasket Hand Hole 10 10-2414 Nut 11 10-231 0 Washer 12 91-8811 Yoke 13 10-4754 Glass, Sight Gauge, 6” 14 90-0039 Rubber & Brass Washer Set 15 10-2728 Kit, Com
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ILLUSTRATED PARTS LIST 200K BTU Boiler Shown Gas Train, 200K Boiler Shown ITEM NO. PART DESCRIPTION NO. 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. 6 94-5046 Burner 7 94-5052 Pilot Brkt 8 08-7119 Orifice, Natural Gas (Brass #30) 8 08-7120 Orifice, Propane (#45 Black) 9 08-7118 Orifice Hood 17
