Market Forge M24G200A-4SP User Manual

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 VICINITY OF THIS OR ANY OTHER APPLIANCE.

Post instructions in a prominent location to be followed in the event the user smells

gas. This information shall be obtained by consulting the local gas supplier.

Form Number: S-2404 REV: E 06/08

Printed in U.S.A. 35 Garvey Street l Everett l MA l 02149

Tel: [phone]

l

Fax: [phone] l Outside MA Fax: [phone]
E-Mail: CUSTSERV@mi.com

An Employee Owned Company

l

Website: www.mi.com

TABLE OF CONTENTS

INTRODUCTION .......................................................................................................................................ii

TO THE KITCHEN MANAGER .........................................................................................................ii

INTRODUCTION ...............................................................................................................................ii

HOW TO USE THIS MANUAL ..........................................................................................................ii

THEORY OF OPERATION FOR GAS BOILER ................................................................................ii

INSTALLATION INSTRUCTIONS (Gas Operated Boiler) ......................................................................1-4

INSTALLING LEGS ...........................................................................................................................1

LEVELING .........................................................................................................................................1

LOWER DEFLECTOR PLATE ..........................................................................................................1

GAS SERVICE CONNECTIONS ......................................................................................................2

ELECTRIC SERVICE CONNECTIONS ............................................................................................2

ISERVICE CONNECTIONS ..............................................................................................................3

INSTALLATION INSTRUCTIONS FOR THE LOWER DEFLECTOR ASSEMBLY ............................4

OPERATING INSTRUCTIONS .................................................................................................................5-6

DAILY OPERATING PROCEDURE ..................................................................................................5

DAILY SHUT DOWN AND CLEANING .............................................................................................5

LIGHTING INSTRUCTIONS, SPARK PILOT ....................................................................................6

ADJUSTMENTS ........................................................................................................................................6

IF GAS PRESSURE IS LOW OR TOO HIGH ...................................................................................6

PRESSURE CONTROL SWITCH ADJUSTMENT ............................................................................7

GENERAL TROUBLE-SHOOTING ..........................................................................................................8-9

TESTING PROCEDURE ...........................................................................................................................10

WATER CONTROL BOARD TESTING PROCEDURE .....................................................................10

ILLUSTRATED PARTS LIST ....................................................................................................................11-17

BOILER BASE CABINET (24”) PARTS LIST ....................................................................................11

PRESSURE SWITCH BOX WITHOUT COVER ...............................................................................12

CONTROL BOX ASSEMBLY WITH & WITHOUT COVER ...............................................................13

PLUMBING SECTION ......................................................................................................................14

PARTS (200,000 BTU) .....................................................................................................................15

PARTS (Gas Train) ............................................................................................................................16

ELECTRICAL INFORMATION ..................................................................................................................18-19

WIRING DIAGRAM FOR NEW GENERATION BOILERS .................................................................18

WIRING SCHEMATIC FOR NEW GENERATION BOILERS ............................................................19

MAINTENANCE ........................................................................................................................................20-21

CLEANING THE BOILER ..................................................................................................................20

REPLACEMENT PARTS ...................................................................................................................20

CLEANING INSTRUCTIONS ............................................................................................................20

APPLICATION INSTRUCTIONS ..............................................................................................................22-23

i

INTRODUCTION

TO THE KITCHEN MANAGER:

Read this manual carefully and in its entirety. Contact Market Forge Ind., Inc. for clarication if necessary.

1.
Protect your kitchen personnel from scalding and other serious injury by providing training programs to ac-

2.
quaint all equipment operators with the correct and safe methods of operation.

Operators must be made aware of the consequences of misuse. Steam producing equipment, no matter

3.
who the manufacturer, is inherently dangerous when misused. The possibility of serious scalding always
exists, the careless and/or untrained operator will be injured.

This equipment must be maintained according to the guidelines in this manual (see “maintenance”). Lack

4.
of maintenance will lead to a potentially hazardous condition and possible liability. Operators should report
any equipment malfunction immediately and steps must be taken to correct the problem before further use
of the equipment is allowed.

Keep this manual for daily reference.

5.

INTRODUCTION:

Market Forge, in the interest of both cost and efciency has designed these steam boilers with the latest automatic

controls in order to make it easier for the operator to use and maintain this equipment. Standard components are

utilized on all models unless variances in size or capacity dictate a divergence from this policy for more efciency

of operation. This parts and service manual is written and illustrated to cover all steam boiler equipment that uses
gas as a source of fuel other than those which have been custom designed under special order.

HOW TO USE THIS MANUAL:

The pictures of components are aids to the identication, disassembly and assembly of parts. The parts listing

provides information necessary for the ordering of replacement parts (proper part names and part numbers). When
requesting parts or service always furnish the model and serial number of your complete unit, this will indicate to
Market Forge Service Personnel the type of boiler that you have. This information can be found on the nameplate
attached to the boiler frame.

THEORY OF OPERATION FOR GAS BOILER:

An explanation of how the control system operates on automatic gas boilers follows:

After the boiler is lled with water to the proper level and the fuel switch is turned ON, the main gas valve will be
activated allowing gas to ow to the main burners that will be ignited by the Spark Pilot. When the boiler builds to
its set pressure, the pressure switch opens. This will open the circuit to the gas valve that will stop the ow of gas

to the main burners. As the pressure in the boiler drops the pressure control switch will again complete the circuit
and build the boiler back to its set pressure. To stop all steam generation place the FILL/ON-OFF switch to the OFF
position.

ii

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 ow 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 in Canada, this appliance is to be in accordance with the
current CAN/CGA-B149(.1 or .2) Installation Code for Gas Burning Appliances and Equipment and/or Local
Codes.

This applicance, when installed, must be electrically grounded in accordance with local codes, or in the absence

►

of local codes, with the National Electric Code, ANSI/NFPA70-Latest Edition. For installation in Canada, All
electrical connections are to be made in accordance with CSA C22.1 Canadian Electrical Code Part 1 and/or
Local Codes.

The boiler and its individual shut off valve must be disconnected from the gas supply piping system during any

►

pressure testing of that system at test pressure in excess of 1/2 psig (3.45 k/PA).
The boiler must be isolated from the gas supply system by closing its individual manual shut off valve during any

►

pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.45 k/PA).
The wiring diagram label is located on the inside of the Lift-Off Front Panel.

►

This product must be installed in a room with adequate air supply.

►

Do not place any objects on or directly against the unit as to block air openings into the combustion chamber.

►

Clearances from both combustible and non-combustible construction are 3” (76mm) from side walls, 6” (152mm)

►

from rear wall. With lower deector plate, shown on page 4, installed this unit is suitable for Installation on Com-

bustible Floors.
This unit is serviceable from the front, do not install in such a manner where a service person cannot remove

►

front panels.

INSTALLING LEGS:

Some models are shipped without legs. A separate carton will contain the legs. If your model is received this way,
be sure to follow the installation instruction sheet packed with the legs.

LEVELING:

In order for the boiler to drain correctly, it is important to use a level on cabinet top both left and right and front-to­back. If not level, adjust feet. On compartment cookers, check the interior shelves for level condition.

LOWER DEFLECTOR PLATE:

The lower deector plate must be installed on the boiler. Be sure to follow the installation instructions located on

page 4.

1

INSTALLATION INSTRUCTIONS

*GAS SERVICE CONNECTIONS:

The boiler is factory adjusted for a gas input of 100, 200 & 300K BTU/HR at the pressure indicated.

a)

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, the only acceptable location for the gas supply shut off valve is under the unit in the space
provided by the legs.

Use new iron or steel pipe complying with the latest ANSI Standard for Wrought-Steel and Wrought-Iron

b)

Pipe, B36, properly threaded, reamed and free from chips, oil and dirt. If pipe dope is used, apply a mod­erate amount leaving two end threads bare. Pipe dope must be resistant to LP gas. Connect the gas line
into the bottom (inlet) side of the shutoff valve. The supply pressure must be at least 1” (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 necessary corrections.

Perform a gas leak test of all newly-made joints, as well as those leading to the main gas control valve.

c)

Use a soap solution, DO NOT USE FLAME.
Natural gas units are equipped with a pressure regulator factory adjusted to give 4” (102mm) water col-

d)

umn manifold pressure.
Propane gas units are equipped with a pressure regulator, factory adjusted, to give 10” (254mm) water

e)

column manifold pressure.
ONLY A LICENSED GAS FITTER SHOULD MAKE GAS LINE CONNECTIONS.

f)

*ELECTRIC SERVICE CONNECTION:

Connect boiler controls to 110/120 volt AC, 60Hz, single phase branch circuit rated 15 amps capacity, using the
three prong plug provided.

* Gas and Electrical connections should be made by licensed tradesmen only.

2

INSTALLATION INSTRUCTIONS

NOTE:

PVC & CPVC PIPE ARE NOT ACCEPTABLE

MATERIALS FOR DRAINS.

WARNING:

DO NOT UNDER ANY CIRCUMSTANCE

CONNECT THE EXHAUST DRAIN LINE

DIRECTLY TO A SEWER LINE.

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/cm

kgcm2) 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 for cold wa-

ter to condenser. Cold water lines will have a max
of 50PSI (3.5 kg/cm
kg/cm2) water pressure.

D Drain - Pipe full 2” (51mm) IPS to ush oor drain

capable of receiving water owing at a max rate

of 5 gal. (19 liters) per minute. DO NOT MAKE
SOLID CONNECTION TO FLOOR DRAIN.

EC Electrical Connection - 120 volt A.C. 60Hz, 1/2”

(13mm) conduit connection or equivalent. Use
wire suitable for a least 90
generator controls is 2 amps.

ST Steam Take-off - Connection for operation of ad-

jacent steam powered equipment.

NOTES: If equipment is installed where elevation exceeds
2,000 feet (609.6 meters) above sea level, specify installa-

tion altitude so that proper gas orices can be provided.

2

) and a min of 25PSI (1.8

2

) and a min of 25PSI (1.8

o

C. Amp for 115 steam

The only available space to supply utilities to the gas boiler

is the 6” (152mm) space between the oor and the cabinet.

Allow 3” (76mm) space from side wall and 6” (152mm) from
real wall if adjoining walls are combustible.

CAUTION: Before connecting water to this unit, water sup­ply should be analyzed to make sure hardness is no greater
than 2.0 grains and pH level is within the range of 7.0-8.5.
Water which fails to meet these standards should be treated
by installation of water conditioner. EQUIPMENT FAILURE
CAUSED BY INADEQUATE WATER QUALITY IS NOT
COVERED UNDER WARRANTY.

WASTE LINE INSTALLATION: The drain port of the unit is
marked with a colored tag and is located at the lower rear left
side of the boiler as viewed from the front. This exhaust line

may be left open if the boiler has to be situated in a tiled oor

depression or a tiled curb section that is equipped with drain
facilities. If this is not the case, then a 2” (51mm) NPT.
drain line must be connected to divert the exhaust to the

oor drain. If it is necessary to use more than three elbows,

increase the size of the waste line accordingly.

3

INSTALLATION INSTRUCTIONS

Lower Deector

200 Boiler 98-3972
300 Boiler 98-3976

Upper Deector

200 Boiler 94-5115
300 Boiler 94-5095

LOWER DEFLECTOR ASSEMBLY

To Install the Lower Deector as shown in Figure 1., the following steps must be
taken:

Locate lower deector as shown in Figure 2. The rear brackets will slide in

1.
openings and allow it to rest in place on frame.

Move lower deector slightly forward to allow front brackets to t over 8-32

2.

studs protruding out from the upper deector plate as shown in Figure 3.
Secure lower deector in place as shown in Figure 1. using 8-32 stainless steel

3.
wing nuts (part number 08-7835).

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.

DAILY OPERATING PROCEDURE

STEP 1 PRESS WATER SWITCH FROM OFF TO ON.
STEP 2 WAIT 5-10 MINUTES FOR WATER TO FILL IN STEAM GENERATOR

(GAUGE GLASS SHOULD BE 2/3 FULL.)
STEP 3 PRESS HEAT SWITCH FROM ON TO OFF AND RELEASE BACK TO ON

WHEN THE LOW WATER LIGHT GOES OFF. GREEN INDICATOR LIGHT
WILL COME ON. (THIS IS NECESSARY TO MANUALLY RESET THE UNIT.)

DAILY SHUT DOWN AND CLEANING

STEP 1 PRESS WATER SWITCH OFF. THIS WILL DRAIN THE STEAM GENERATOR.
STEP 2 AFTER STEAM GENERATOR HAS COMPLETELY DRAINED REPEAT

STEAPS 1 & 2 OF DAILY OPERATING PROCEDURE.
(WATER TO REMAIN IN STEAM GENERATOR UNTIL NEXT DAILY USE.)

5

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 ow 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 the water

►

switch is in the OFF position.

LIGHTING INSTRUCTION, SPARK PILOT: (Be sure boiler drain valve is closed)

Press water switch from OFF to ON.

1.

Wait 5 to 10 minutes for water to ll in the boiler (Gauge glass should be 2/3 full).

2.
Press the heat switch from ON to OFF and release back to ON position when the low water light goes OFF.

3.
Green indicator light will come on (This is necessary to manually reset the unit).

ADJUSTMENTS

A. IF GAS PRESSURE IS LOW:

Check your gas supply line for a restriction. If no restriction exists, check with your Natural gas supplier to
provide at least 5” of water column pressure in the gas supply line. If no restriction exists and Propane gas is
being used, the tank pressure regulator should be adjusted to supply at least 11” of water column pressure
in the gas supply line. If this adjustment cannot be made to your satisfaction, the gas supplier should be noti-

ed.

B. IF GAS PRESSURE IS TOO HIGH:

Adjust the pressure regulator on the boiler gas valve to reduce the pressure if Natural gas is being used. If
Propane gas is being used, adjust the pressure regulator supplied by the gas supplier. If the regulator cannot
be adjusted, notify the gas supplier.

6

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.

Start boiler and allow pressure to build up to operating level - 7 PSI (1kg/cm²).

1.
Check boiler pressure gauge. If gauge indicates 5 to 7 PSI, pressure control switches are properly ad-

2.
justed.

If boiler does not come on when pressure gauge reads 7 PSI and does not go off when pressure gauge

3.
reads 7 PSI, proceed as follows:

WARNING: Because power must be on to adjust pressure switches, be sure to protect against electrical shock.

Remove screw and lift front cover off control box.

a)

Hand adjust operating pressure control switch and high limit pressure control switch by turning adjusting

b)

nut (Knurled knob) clockwise to raise and counter clockwise to lower actuation point. Switch should be
set so that boiler comes on when boiler pressure gauge reads 5 PSI and goes off when gauge reads 7
PSI. Switch should be set so that boiler will shut off if pressure reaches 15 PSI.

The actuation value (differential) is factory set and cannot be changed.

c)

The cold water condensor thermostat is preset at factory.

d)

Repeat steps, 1, 2, and 3. If 45 to 7 PSI boiler pressure gauge reading is obtained during boiler opera-

e)

tion, adjustment is correct. If proper adjustment cannot be made consult Trouble-Shooting Guide in this
manual.

After making adjustments, replace cover on pressure switch box and screw.

f)

7

GENERAL TROUBL-SHOOTING

TROUBLE POSSIBLE CAUSE REMEDY

Pilot will not ignite or does not hold. Gas not reaching unit.

Water enters boiler very slowly. Clogged strainer screen on

Boiler overlls with water Probes scaled.

1.
Main “gas cock knob” not in

2.
ON position.

Air pocket or clog in gas line.

3.
Defective wiring or poor con-

4.
nection at pilotstat power unit.

Defective switching across

5.
either the water level control or
pressure switches.

Defective gas valve.

6.

1.

water ll solenoid valve

Debris or lime accumulation on

2.

seat of water ll valve.

1.
Water supply valve fails to

2.
close.

Defective water level control.

3.

Check to make sure gas is on

1.
and gas line is purged of air.

Depress and turn “main gas

2.
cock” to pilot position - (refer to
lighting instructions).

Purge or blow out gas line.

3.
Check - replace or tighten.

4.
Make continuity check - replace

5.
units that are defective.

Replace gas valve.

6.
Clean or replace strainer

1.
screen. (P/N 08-4871).

Clean valve seat

2.

Clean.

1.
Clean valve seat or replace

2.
valve.

Follow the test procedure on

3.
page 11. Replace if defective.

Main Burners will not ignite or will
not remain lighted.

Boiler fails to build up any pressure
when the water is at the correct
level and the fuel switch is turned
on.

Water level in gauge glass

uctuates up and down.

No water in boiler.

1.
Main gas cock or supply line

2.
not open.

Pressure switch set too low.

3.
No voltage to gas valve.

4.
Gas valve defective.

5.

Check to see that main gas is

1.
turned on.

Check to see that gas valve is

2.
in burners “on” position.

Current ow is broken at water

3.
level control (ascertain with
continuity check).

Current ow is broken at pres-

4.
sure control or high limit control
switches (ascertain with conti­nuity check).

Top shutoff valve on water

1. Open.1.
gauge glass is closed.

1.

2.

3.

4.

5.

1.

2.

3.

4.

Check to be sure water switch
is on. Check to be sure main
water supply is on and the elec­trical supply to unit is on.

Open.
Reset - if continuity check

shows to be defective - replace.
Check main fuse.
Replace.
Turn on.
Turn to burners “on”.
Check for voltage thru right

side of control board, replace if
defective.

Re-adjust to proper setting ­refer to instruction for re-adjust­ment, replace if defective.

8

GENERAL TROUBL-SHOOTING

TROUBLE POSSIBLE CAUSE REMEDY

Boiler fails to reach full operating
pressure of 5 lbs. or 15 lbs.

Pressure gauge reads inaccu-

1.
rately.

Pressure control and high limit

2.
control switches are out of ad­justment.

Safety valve not seating prop-

3.
erly.

Water level too high.

4.
Air vent not venting properly.

5.

Insufcient ames on burners

6.
or improper gas supply.

Replace.

1.
Follow instructions for readjust-

2.
ing. (page 10)

Purge manually or replace.

3.
Adjust water level control

4.

- check water feed valve for
sticking - clean or replace.

Replace.

5.
See instructions on gas adjust-

6.
ments. (page 5)

Boiler fails to cut off after reaching
operating pressure.

Safety valve blows off prematurely. Pressure set too high.

Boiler builds up to pressure, shuts
down, fails to come back on.

Water does not enter boiler. Main water supply off.

Cold water condenser does not
function.

Air vent leaking. Not closing.1. Replace.1.

Pressure switch set too high or

1.
defective.

Gas valve fails to cut off gas

2.
supply when demands of pres­sure switch have been met.

1.
Pressure gauge reads incor-

2.
rectly.

Lime or debris on seat of valve

3.

1. High limit switch set to low

1. 1. Follow instructions for read­or operating pressure control
switch set too high.

1.
Power not reaching unit.

2.
Probes Dirty.

3.
Water level control board defec-

4.
tive.

Solenoid valve defective

5.

Main water supply off.

1.
Thermostat defective.

2.
Loose coil nut.

3.
Solenoid coil not energized.

4.

1.

2.

1.

2.

3.

1.

1.

2.

3.

4.

5.

1.

2.

3.

4.

Adjust or replace if defective.
Replace gas valve.

Readjust pressure control.
(page 10)

Replace.
Purge or replace.

justing, see (page 10) Replace
if defective.

Turn on.
Check main fuse or circuit.
Remove & Clean
See page 11 for test procedure.

If Voltage is veried at solenoid

coil, but fails to open, replace
solenoid.

Turn on.
Replace if defective.
Tighten coil nut.
Check coil for continuity, if open

replace.

9

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.

»

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 terminals ‘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 Terminals:

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’ terminals.

‘LED l’ should turn off after a 10 sec-

»

ond delay.
Use V-O-M to verify that there is no

»

power at the ‘FW (NO)’ terminal.
Remove jumper from ‘FW HIGH’ and

»

‘GND’ terminals. . ‘LED l’ should turn

»

on.
Use V-O-M to verify that there is pow-

»

er at the ‘FW(NO)’ terminal.

Test Primary Low Water Function:

Connect jumper wire to ‘LW(1) and

»

‘GND’ terminals.
‘LED 3’ should turn on.

»

Remove jumper wire from ‘LW(1)’ and

»

‘GND’ terminals.
‘LED 3’ should turn off after a 3 second

»

delay.
Connect jumper wire to ‘LW(1)’ and

»

‘GND’ terminals.
‘LED 3’ should turn on.

»

IMPORTANT:

Jumper wire between ‘LW(1) and ‘GND’

terminals 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 2’ 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’ terminals.

»

‘LED 2’ 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’ terminals.

»

‘LED 2’ 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’ terminals.

»

‘LED 2’ should remain off.

IF ANY OF THE FUNCTIONS DO

NOT WORK, REPLACE THE

BOARD!

IF ALL FUNCTIONS WORK,

TROUBLE-SHOOTING OTHER

COMPONENTS WILL BE

REQUIRED!

10

ILLUSTRATED PARTS LIST

24” Boiler Base Cabinet Shown

ITEM NO. PART

NO.

1 91-8892 Flue Outer, 24” Front
1 91-8938 Flue Outer
2 91-8893 Flue Outer, 24” Back
2 91-2713 Flue Outer, 36” Back
3 98-0593 Flue Inner
3 91-8936 Flue Inner Assembly, 300k Boiler
4 08-5894 Market Forge Nameplate Logo
5 91-5795
6 94-5007 Panel, Front Assembly, 24”
6 94-5006 Panel, Front
7 10-0631 Leg, 6”
7
7 08-5211 Leg, 10”
7 08-5208 Leg, Flanged 6”
7 10-0326
8 98-3968 Trim, Edge

9 98-3978 Glass
10 98-3991 Gasket,
11 98-4010 Panel, Side (Single Panel)
12 98-3995
12 98-3996 Panel, Rear Assembly, 36”
13 94-5011

08-5206 Leg, 8”

Handle, Front

Caster, 5”

Panel, Rear Assembly, 24”

Panel Clips (not shown)

, 36” Front

Assembly, 100 & 200k Boiler

Assembly, 36”

Adhesive

DESCRIPTION

11

ILLUSTRATED PARTS LIST

Pressure Switch Box, without Cover

ITEM NO. PART

NO.

1 94-5064 Box, Pressure Switch
2
3
4 98-3875 Switch, Drain By-Pass
5 08-7933 Manifold, Pressure Switches
6
7 09-4844 Union Elbow, 1/2”

10-8410 Pressure Switch, Hi-Limit
10-8411 Pressure Switch, Operating

10-4804 Pressure Gauge

DESCRIPTION

12

ILLUSTRATED PARTS LIST

Control Box Assembly, with and without Cover

ITEM NO. PART

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, W

6 94-5022 Ignition Module

7

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

08-6472 Relay Tube

ater Level Control

DESCRIPTION

13

ILLUSTRATED PARTS LIST

Plumbing, Left Side Gas Boiler, 24”

ITEM NO. PART

NO.

1 10-0239 Hose, Drain 1”

2 10-4137 Clamp Hose

3 91-6927 Box Drain

4 10-7955 V

5 10-1058 V

6 10-1311 Valve, Drain, 120V

7 08-4822 Valve, Boiler Feed

8 08-7959 Condenser, 3/8” Hose, 21” Long

9 98-3894 Copper
10 98-3914 Comp Fitting, 3/4”
11 98-1401 V
12 10-0287 Hose, Drain, 3/4”
13
14 08-7974 Clamp, Hose
15 98-3892 Condenser Thermostat
16 10-1152 Plug

10-4137 Clamp, Hose

alve, Safety, 15 PSI
alve, Cold Water Condenser, 120V

alve, Check

Assembly

, Nozzle

DESCRIPTION

14

ILLUSTRATED PARTS LIST

Front View Gas Boiler, 24”, 200K

ITEM NO. PART

NO.

1 08-4900 W
2 94-5023 Gas Valve
3 94-5033 Gas Manifold, 100K & 200K Boilers
3 94-5034 Gas Manifold, 300K Boilers
4 10-3661 Drain V
5 10-1311 Drain Valve, Automatic
6 91-511
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
12 94-5128 Gas Valve, 120V, Propane Kit
13 08-7970 Hose, Water, 20”
14 98-3864 Flex Conduite

2 Probe Plate Assy

ater Inlet, Manual Valve

alve, Maunal

DESCRIPTION

15

ILLUSTRATED PARTS LIST

Gas Train, 200K BTU Boiler Shown

ITEM NO. PART NO. DESCRIPTION

1 98-3923 V

1A 08-7970 Bleeder Hose

2 10-7955 V
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

9 08-4415 Gasket Hand Hole
10 10-2414
11 10-2310 W
12 91-8811 Yoke
13 10-4754 Glass, Sight Gauge, 6”
14 90-0039 Rubber & Brass W
15 10-2728 Kit, Complete Includes: Valves, Glass
16 98-3928 Elbow 1/2”, Side Outlet
17 98-3944 Stud, 1/4-20

ent, Bleeder

alve, Safety, 15 PSI

}

Cover Hand Hole

Nut

asher

asher Set

16

ILLUSTRATED PARTS LIST

Gas Train, 200K Boiler Shown

ITEM NO. PART

NO.

1 08-7832 T
2 10-1154 Compression Coupling
3 98-3890 Pilot Tube
4 94-5099 Spark Pilot and Igniter
5 94-5129 Pilot Orice, Prop.
6 94-5046 Burner
7 94-5052 Pilot Brkt
8 08-7119 Orice, Natural Gas (Brass #30)
8
9 08-7118 Orice Hood

08-7120 Orice, Propane (#45 Black)

ube, Flex, Gas Line

17

DESCRIPTION

ELECTRICAL INFORMATION

Wiring Diagram for New Generation Boilers - 100K, 200K and 300K BTU

18

ELECTRICAL INFORMATION

Schematic Diagram for New Generation Boilers - 100K, 200K and 300K BTU

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. Because no water supply can be accurately compared with that of
another, this section should not be regarded as fool proof. A stepped-up, more frequent cleaning schedule may be
required when excessive impurities exist.

The Cleaning schedule should be performed two or more times per year as governed by the local water condi­tions. Market Forge recommends the use of its “cathodic descaler” to protect the inner boiler walls and components
against rust, scale and lime deposits. The normal effectiveness of a descaler is one year.

The schedule for changing the “cathodic descaler” may be timed to the cleaning schedule or accelerated as noted
above.

Market Forge qualied service agencies are available to establish a suitable schedule for TOTAL CONCEPT clean­ing and descaler replacement.

REPLACEMENT PARTS NEEDED TO COMPLETE THESE INSTRUCTIONS

NUMBER REQUIRED PART NO.

1 Hand-hole Cover Gasket 08-4415
1 Set of Rubber & Brass Washers 90-0039
1 Probe Plate Gasket (Gas Only) 08-4413
1 Market Forge Cathodic Descaler (all boilers) new style 08-0049
1 Dynaseal Washer 10-1135

CLEANING INSTRUCTIONS:

Move the HEAT and POWER switch to their OFF positions.On electric models also turn off the electric

1.
power at the main switch. This will allow the boiler to empty.

WARNING: (ALL BOILERS ) DISCONNECT THE 115 VOLT POWER SUPPLY.

Remove the hand-hole cover as follows: (Refer to Fig. 1)

2.

Remove pressure switch box at the plumbing union and move it out of the way.

a)

With an open end wrench back off the hex-nut, counterclockwise, so only two threads are holding it.

b)

Then remove the pressure switch box and set aside.
With a blunt instrument, strike the hand-hole cover until its seal is broken.

c)

Remove the hex-nut from the remaining two threads, slide off the washer and channel yoke do not allow

d)

the hand-hole cover to drop inside.
Remove the hand-hole cover by turning it so that it will pass through the opening. Remove the bolt and

e)

dynaseal. Discard the hand-hole gasket and dynaseal washer.

Fig. 1.

20

MAINTENANCE

Clean rust, scale and lime deposits from the inside of the boiler with a wire brush.

3.

DO NOT DAMAGE COPPER HEATING ELEMENTS - BRUSH LIGHTLY. WORK DEPOSITS TO REAR

CORNER AND REMOVE WITH PUTTY KNIFE.

After removing all debris, ush out with clean water through the hand-hole and drain .

4.
Clean the hand-hole cover with a wire brush and wash. Be sure the areas that contact the gasket and dy-

5.
naseal are clean and smooth.

Fig. 2. Fig. 3.

To protect against further scale and corrosion remove the old cathodic descaler. Install a New Market Forge

6.

Cathodic Descaler. See g. 2 or 3, page 43.

Without the use of gasket compound, re-install the handhole cover using a new gasket and dynaseal

7.
washer. A torque of approximately 50 in. lbs. is required to reset the hex nut. Reinstall the pressure switch
box. Bring the boiler to operating pressure. If a leak appears, at the handhole cover, relieve the pressure in
the boiler and retighten the hex nut.

Clean the water gauge glass as follows:

8.

Move the heat and power switch to their off positions. This will allow the boiler to empty.

a)

Unscrew the ttings from both valves and slide them toward the center of the guage glass. Push the

b)

water gauge glass downward compressing the rubber washer in the lower valve allowing the glass
to be removed.

Remove and discard the two rubber and brass washers. Slip off the two valve ttings and clean the wa-

c)

ter gauge glass.

Reassemble by reversing the above steps with new rubber and brass washers . (see g. 4)

d)

Fig. 4.

21

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. Those boilers designated as being automatic
must be energized in order to close the drain valve.

Total Concept is designed to be used with water between
160°F to 200°F.

Preheating is required on both automatic and manual
boilers to raise the water temperature to the acceptable
range. (160°F to 200°F).

For manual boilers, make certain drain valve is tightly
closed.

On Market Forged boilers manufactured after 8/84; your
unit is equipped with an access plug in the steam header
line. This location should be used to add cleaner/des­caler to boiler chamber during maintenance.

On Market Forged boilers manufactured before 8/84; ac­cess to boiler chamber should be gained through either
the vent-rite or the pressure relief valve.

Fig. 2

2. Energize heating circuit to pre-heat unit.

Fig. 3

Total Concept is a NSF listed nonfood product. This is
a liquid acid (nonmuriatic) product that works without
fumes, odors, and hazards associated with other harsh
chemicals.

BOILER TREATMENT CLEANING INSTRUCTIONS:

After determining proper location for cleaner/descaler
to be added: Read complete instructions thoroughly; in­cluding all warning and cautionary statements.

Fig. 1

1. Energize boiler and ll to operating level.

Fig. 4

3. AUTOMATIC - After unit is pre-heated, cycle the pow­er switch to the OFF position then immediately back
to the ON position.

22

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 rst notch to

a 45o angle.

5. Install the tubing rmly over the tip of the pouring

cap.

Fig. 6

6. Energize compartment to release steam pressure in
boiler to “0” PSI before removing pipe plug.

7. Remove the plug from the access port on the steam
header pipe inside cabinet doors.

CAUTION: HE7DER PIPE & ACCESS PLUG ARE HOT.

Fig. 7

8. Feed the tubing through the access port in the boiler
compartment.

NOTE: A minimum of 12” must be inserted.

Fig. 9

Tilt the container, pour the contents into the unit.

9.

When empty, rell the container with hot tap water

10.

and add to boiler for cleaning. Repeat twice. This
additional 2 gallons of water will cause the low water
probe to be immersed in cleaner/descaler solution.
Replace access plug.

After rinsing the container, place tubing inside the

11.

bottle, cover with shipping cap, dispose of properly.
DO NOT REUSE CONTAINER.

DO NOT ENERGIZE HEATERS. Allow 2 hours for

12.

cleaning.
After time has elapsed, drain the boiler.

13.

Rell the boiler and drain. Repeat this step twice.

14.

Bring the boiler to temperature and cycle steam to

15.

the cooker compartment to purge cleaner/descaler
from the steam supply lines. Repeat this step twice.

Boiler is now ready for use.

16.

23