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]

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

An Employee Owned Company

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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