Market Forge Industries M36G300A-4SP, M36G100A-4SP, M36G200A-4SP, M24G200A-4SP Owner's Manual

0

OWNER’S MANUAL

WARNING:

IMPROPER INSTALLATION, ADJUSTMENT,

ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE

PROPERTY DAMAGE, INJURY OR DEATH. READ THESE

INSTALLATION, OPERATION AND MAINTENANCE

INSTRUCTIONS THOROUGHLY BEFORE INSTALLING

OR SERVICING THIS EQUIPMENT.

Form Number: S-2404 REV. F 05/13
Printed in USA 35 Garvey Street, Everett, MA 02149

Telephone [phone], Fax [phone]

[e-mail], www.mfii.com

IMPORTANT:

POST INSTRUCTIONS IN A PROMINET
LOCATION TO BE FOLLLOWED IN THE EVENT
THE USER SMELLS GAS. THIS INFORMATION

SHALL BE OBTAINED BY CONSULTING THE

LOCAL GAS SUPPLIER.

FOR YOUR SAFETY:

DO NOT STORE OR USE GASOLINE OR OTHER

FLAMMABLE VAPORS OR LIQUIDS IN THE

VICINITY OF THIS OR ANY OTHER APPLIANCE.

Gas Operated Boilers

MODELS: □ M24G100A-4SP □ M24G200A-4SP

□ M36G100A-4SP □ M36G200A-4SP
□ M36G300A-4SP

1

Table of Contents

INTRODUCTION ............................................................................................................................................. 2

To the Kitchen Manager: .......................................................................................................................... 2

INSTALLATION INSTRUCTIONS ...................................................................................................................... 3

GAS OPERATED BOILERS ........................................................................................................................... 3

INSTALLING LEGS: ..................................................................................................................................... 3

LEVELING: .................................................................................................................................................. 3

LOWER DEFLECTOR PLATE: ....................................................................................................................... 3

GAS SERVICE CONNECTIONS: * ................................................................................................................. 4

ELECTRIC SERVICE CONNECTION: * .......................................................................................................... 4

SERVICE CONNECTIONS: ........................................................................................................................... 5

LOWER DEFLECTOR ASSEMBLY ................................................................................................................. 6

CONTROL PANEL: ...................................................................................................................................... 7

OPERATING THE STEAM GENERATOR: ..................................................................................................... 7

OPERATING INSTRUCTIONS .......................................................................................................................... 7

CAUTION: BE SURE TO READ: ................................................................................................................... 8

LIGHTING INSTRUCTION, SPARK PILOT: .................................................................................................... 8

ADJUSTMENTS .............................................................................................................................................. 8

A. IF GAS PRESSURE IS LOW: ..................................................................................................................... 8

B. IF GAS PRESSURE IS TOO HIGH: ............................................................................................................ 8

SETTING THE BOILER CONTROL PRESSURE SWITCHES: ............................................................................ 9

PRESSURE CONTROL SWITCH ADJUSTMENT: ........................................................................................... 9

GENERAL TROUBLE SHOOTING ................................................................................................................... 10

TESTING PROCEDURE .................................................................................................................................. 12

WATER CONTROL BOARD TESTING PROCEDURE.................................................................................... 12

ILLUSTRATED PARTS LIST ............................................................................................................................ 13

BOILER BASE - 24” ................................................................................................................................... 13

PRESSURE SWITCH BOX, WITHOUT COVER ............................................................................................ 14

CONTROL BOX ASEMBLY, WITH & WITHOUT COVER ............................................................................. 15

PLUMBING, LEFT SIDE GAS BOILER – 24” ............................................................................................... 16

FRONT VIEW GAS BOILER, 200K – 24” .................................................................................................... 17

GAS TRAIN, 200K GAS BOILER ................................................................................................................. 18

GAS TRAIN, 200K GAS BOILER ................................................................................................................. 19

ELECTRICAL INFORMATION......................................................................................................................... 20

Wiring Diagram for New Generation Boilers – 100K, 200K, 300K BTU .................................................. 20

Schematic Diagram for New Generation Boilers – 100K, 200K, 300K BTU ............................................. 21

MAINTENANCE ............................................................................................................................................ 22

Cleaning the Boiler: ................................................................................................................................. 22

CLEANING INSTRUCTIONS: ..................................................................................................................... 22

APPLICATION INSTRUCTIONS ...................................................................................................................... 24

Application Instructions for Total Concept Descaler Cleaning of the Boiler .......................................... 24

2

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.
The possibility of serious scalding always exists; the careless and/or untrained operator
will be injured.

4. This equipment must be maintained according to the guidelines in this manual (see

“maintenance”). Lack 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.

5. Keep this manual for daily reference.

Market Forge, in the interest of both cost and efficiency 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 efficiency 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 identification, 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 filled with water to the proper level and the fuel switch is turned ON, the
main gas valve will be activated allowing gas to flow 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 flow 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.

3

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 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 appliance, 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 PSI (0.03

kg/cm2).

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 PSI (0.03 kg/cm2).

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

sidewalls, 6” (152mm) from rear wall. With lower deflector plate, shown on page 4, installed this

unit is suitable for Installation on Combustible 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-to-back. If not level, adjust feet. On compartment cookers, check the interior shelves for level
condition.

LOWER DEFLECTOR PLATE:

The lower deflector plate must be installed on the boiler. Be sure to follow the installation instructions
located on page 4.

4

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

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

and Wrought-Iron 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.

c) Perform a gas leak test of all newly-made joints, as well as those leading to the main gas

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

d) Propane gas units are equipped with a pressure regulator, factory adjusted, to give 10”

(254mm) water column manifold pressure.

e) ONLY A LICENSED GAS FITTER SHOULD MAKE GAS LINE CONNECTIONS.

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.

5

SERVICE CONNECTIONS:

Gas Operated

G

Gas Connection - 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. tubing for cold
water to condenser. Cold water lines will have a
max of 50PSI (3.5 kg/cm2) and a min of 25PSI (1.8

kg/cm2) water pressure.

D

Drain - Pipe full 2” (51mm) IPS to flush floor drain
capable of receiving water flowing at a max rate
of 5 gallons (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 90oC. Amp for 115 steam
generator controls is 2 amps.

ST

Steam Take-off - Connection for operation of
adjacent steam powered equipment.

NOTES: If equipment is installed where elevation exceeds
2,000 feet (609.6 meters) above sea level, specify
installation altitude so that proper gas orifices can be
provided.

The only available space to supply utilities to the gas

boiler is the 6” (152mm) space between the floor and the
cabinet. Allow 3” (76mm) space from side wall and 6”

(152mm) from real wall if adjoining walls are
combustible.

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 floor 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 floor drain. If it is
necessary to use more than three elbows, increase the

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.

WARNING: DO NOT UNDER ANY

CIRCUMSTANCE CONNECT THE EXHAUST

DRAIN LINE DIRECTLY TO A SEWER LINE.

NOTE: PVC & CPVC PIPE ARE NOT ACCEPTABLE

MATERIALS FOR DRAINS.

INSTALLATION INSTRUCTIONS

6

INSTALLATION INSTRUCTIONS

LOWER DEFLECTOR

200K Boiler

98-3972

300K Boiler

98-3976

UPPER DEFLECTOR

200K Boiler

94-5115

300K Boiler

94-5095

LOWER DEFLECTOR ASSEMBLY

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

1. Locate lower deflector as shown in Figure 2. The rear brackets will slide in openings and

allow it to rest in place on frame.

2. Move lower deflector slightly forward to allow front brackets to fit over 8-32 studs

protruding out from the upper deflector plate as shown in Figure 3.

3. Secure lower deflector in place as shown in Figure 1. using 8-32 stainless steel wing nuts

(part number 08-7835).

7

OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS FOR 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: STEP 1 PRESS WATER SWITCH OFF. THIS WILL DRAIN THE STEAM

GENERATOR.

STEP 2: STEP 2 AFTER STEAM GENERATOR HAS COMPLETELY DRAINED REPEAT

STEP 3: STEPS 1 & 2 OF DAILY OPERATING PROCEDURE.(WATER TO REMAIN IN

STEAM GENERATOR UNTIL NEXT DAILY USE.)

CONTROL PANEL:

MODELS: • M24G100A - 4SP

• M24G200A - 4SP

• M36G100A - 4SP

• M36G200A - 4SP

• M36G300A - 4SP

OPERATING THE STEAM GENERATOR:

OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS

8

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

the water switch is in the OFF position.

LIGHTING INSTRUCTION, SPARK PILOT:

(Be sure boiler drain valve is closed)

1. Press water switch from OFF to ON.

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

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

goes OFF. 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 notified.

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.

9

ADJUSTMENTS

WARNING:

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

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

gauge reads 7 PSI, proceed as follows:

a) Remove screw and lift front cover off control box.
b) Hand adjust operating pressure control switch and high limit pressure control switch by turning

adjusting 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.

c) The actuation value (differential) is factory set and cannot be changed.
d) The cold water condenser thermostat is preset at factory.
e) Repeat steps, 1, 2, and 3. If 45 to 7 PSI boiler pressure gauge reading is obtained during boiler

operation, adjustment is correct. If proper adjustment cannot be made consult Trouble­Shooting Guide in this manual.

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

10

TROUBLE

POSSIBLE CAUSE

REMEDY

Pilot will not ignite or does not
hold.

a. Gas not reaching unit.
b. Main “gas cock knob” not in

ON position.
c. Air pocket or clog in gas line.
d. Defective wiring or poor

connection at pilots at power

unit.
e. Defective switching across

either the water level control

or pressure switches.

f. Defective gas valve.

a. Check to make sure gas is

on and gas line is purged of
air.

b. Depress and turn “main gas

cock” to pilot position - (refer

to lighting instructions).
c. Purge or blow out gas line.
d. Check - replace or tighten.
e. Make continuity check –

replace units that are

defective.

f. Replace gas valve.

Water enters boiler very slowly.

a. Clogged strainer screen on

water fill solenoid valve

b. Debris or lime accumulation

on seat of water fill valve.

a. Clean or replace strainer

screen. (P/N 08-4871).

b. Clean valve seat

Boiler overfills with water.

a. Probes scaled.
b. Water supply valve fails to

close.

c. Defective water level control.

a. Clean.
b. Clean valve seat or replace

valve.
c. Follow the test procedure on

page 12. Replace if

defective.

Main Burners will not ignite or will
not remain lighted.

a. No water in boiler.
b. Main gas cock or supply line

not open.
c. Pressure switch set too low.
d. No voltage to gas valve.

e. Gas valve defective.

a. 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.
b. Open.
c. Reset - if continuity check

shows to be defective -

replace.
d. Check main fuse.

e. Replace.

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

a. Check to see that main gas

is turned on.

b. Check to see that gas valve

is in burners “on” position.

c. Current flow is broken at

water level control (ascertain
with continuity check).

d. Current flow is broken at

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

a. Turn on.
b. Turn to burners “on”.
c. Check for voltage thru right

side of control board, replace

if defective.
d. Re-adjust to proper setting -

refer to instruction for re-

adjustment, replace if

defective.

Boiler fails to cut off after
reaching
operating pressure.

a. Pressure switch set too high

or defective.

b. Gas valve fails to cut off gas

supply when demands of
pressure switch have been
met.

a. Adjust or replace if defective.
b. Replace gas valve.

Water level in gauge glass
fluctuates up and down.

a. Top shutoff valve on water

gauge glass is closed.

a. Open.

GENERAL TROUBLE SHOOTING

11

GENERAL TROUBLE SHOOTING

TROUBLE

POSSIBLE CAUSE

REMEDY

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

a. Pressure gauge reads

inaccurately.

b. Pressure control and high

limit control switches are out
of adjustment.

c. Safety valve not seating

properly.
d. Water level too high.
e. Air vent not venting properly.
f. Insufficient flames on

burners or improper gas

supply.

a. Replace.
b. Follow instructions for

readjusting (page 9).
c. Purge manually or replace.
d. Adjust water level control -

check water feed valve for

sticking - clean or replace.
e. Replace.
f. See instructions on gas

adjustments( page 8).

Safety valve blows off
prematurely.

a. Pressure set too high.
b. Pressure gauge reads

incorrectly.

c. Lime or debris on seat of

valve

a. Readjust pressure control

(page 9).

b. Replace.

c. Purge or replace.

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

a. High limit switch set to low or

operating pressure control
switch set too high.

a. Follow instructions for

readjusting, see (page 9)
Replace if defective.

Water does not enter boiler.

a. Main water supply off.
b. Power not reaching unit.
c. Probes Dirty.
d. Water level control board

defective.

e. Solenoid valve defective

a. Turn on.
b. Check main fuse or circuit.
c. Remove & Clean
d. See page 12 for test

procedure.

e. If Voltage is verified at

solenoid coil, but fails to
open, replace solenoid.

Cold water condenser does not
function.

a. Main water supply off.
b. Thermostat defective.
c. Loose coil nut.
d. Solenoid coil not energized.

a. Turn on.
b. Replace if defective.
c. Tighten coil nut.
d. Check coil for continuity, if

open replace.

Air vent leaking.

a. Not closing.

a. Replace.

12

TESTING PROCEDURE

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 find 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

second 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

power at the ‘FW(NO)’ terminal.

Test Primary Low Water Function:

 Connect jumper wire to ‘LW(1)

and‘GND’ terminals.

 ‘LED 2’ should turn on.
 Remove jumper wire from ‘LW(1)’

and ‘GND’ terminals.

 ‘LED 2’ should turn off after a 3

second delay.

 Connect jumper wire to ‘LW(1)’ and

‘GND’ terminals.

 ‘LED 2’ should turn on.

 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 3’ 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 3’ 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 3’ should remain off.

IMPORTANT:

Jumper wire between ‘LW(1) and
‘GND’ terminals must remain in place

to test secondary low water function.

IF ANY OF THE FUNCTIONS DO NOT

WORK, REPLACE THE BOARD!

Test Secondary Low Water Function:

 Connect jumper wire to ‘LW(2)’ and

‘GND’ terminals.

 ‘LED 3’ should remain off.

IF ALL FUNCTIONS WORK, TROUBLE-

SHOOTING OTHER COMPONENTS WILL

BE REQUIRED!

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.

LED 1

LED 2

LED 3

RESET

LW2

GND

LW1

FW - HIGH

HTA NO

LO LITE (NC)

FW (NO)

L1

L2

WATER CONTROL BOARD TESTING PROCEDURE

13

ILLUSTRATED PARTS LIST

ITEM NO.

PART NO.

DESCRIPTION

1

91-8892

Flue Outer, 24” Front

91-8938

Flue Outer, 36” Front

2

91-8893

Flue Outer, 24” Back

91-2713

Flue Outer, 36” Back

3

98-0593

Flue Inner Assembly, 100 & 200k Boiler

91-8936

Flue Inner Assembly, 300k Boiler

4

08-5894

Market Forge Nameplate Logo

5

91-5795

Handle, Front

6

94-500

Panel, Front Assembly, 24

94-5006

Panel, Front Assembly, 36”

7

10-0631

Leg, 6”

08-5206

Leg, 8”

08-5211

Leg, 10”

08-5208

Leg, Flanged 6”

10-0326

Caster, 5”

8

98-3968

Trim, Edge

9

98-3978

Glass

10

98-3991

Gasket, Adhesive

11

98-4010

Panel, Side (Single Panel)

12

98-3995

Panel, Rear Assembly, 24”

98-3996

Panel, Rear Assembly, 36”

13

94-5011

Panel Clips (not shown)

3 2 1

4

11

12

6

8

5 7 10 8 8

BOILER BASE - 24”

14

ILLUSTRATED PARTS LIST

ITEM NO.

PART NO.

DESCRIPTION

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

7

09-4844

Union Elbow, 1/2”

3

2

1 7 4 5 6

PRESSURE SWITCH BOX, WITHOUT COVER

15

ILLUSTRATED PARTS LIST

ITEM NO.

PART NO.

DESCRIPTION

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

CONTROL BOX ASEMBLY, WITH & WITHOUT COVER

16

ILLUSTRATED PARTS LIST

ITEM NO.

PART NO.

DESCRIPTION

1

10-0239

Hose, Drain 1”

2

10-4137

Clamp Hose

3

91-6927

Box Drain Assembly

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

Condenser, 3/8” Hose, 21” Long

9

98-3894

Copper, Nozzle

10

98-3914

Comp Fitting, 3/4”

11

98-1401

Valve, Check

12

10-0287

Hose, Drain, 3/4”

13

10-4137

Clamp, Hose

14

08-7974

Clamp, Hose

15

98-3892

Condenser Thermostat

16

10-1152

Plug

PLUMBING, LEFT SIDE GAS BOILER – 24”

17

ILLUSTRATED PARTS LIST

ITEM NO.

PART NO.

DESCRIPTION

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, Manual

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

12

94-5128

Gas Valve, 120V, Propane Kit

13

08-7970

Hose, Water, 20”

14

98-3864

Flex Conduite

FRONT VIEW GAS BOILER, 200K – 24”

18

ILLUSTRATED PARTS LIST

ITEM NO.

PART NO.

DESCRIPTION

1

98-3923

Vent, Bleeder

1A

08-7970

Bleeder Hose

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; Part No. 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

10-2310

Washer

12

91-8811

Yoke

13

10-4754

Glass, Sight Gauge, 6”

14

90-0039

Rubber & Brass Washer Set

15

10-2728

Kit, Complete Includes: Valves, Glass

16

98-3928

Elbow 1/2”, Side Outlet

17

98-3944

Stud, 1/4-20

18

98-3945

Kep Nut

GAS TRAIN, 200K GAS BOILER

19

ILLUSTRATED PARTS LIST

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.

6

94-5046

Burner

7

94-5052

Pilot Brkt

8

08-7119

Orifice, Natural Gas (Brass #30)

08-7120

Orifice, Propane (#45 Black)

9

08-7118

Orifice Hood

GAS TRAIN, 200K GAS BOILER

20

ELECTRICAL INFORMATION

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

21

ELECTRICAL INFORMATION

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

22

MAINTENANCE

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 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 qualified service agencies are available to establish a suitable schedule for TOTAL
CONCEPT cleaning and descaler replacement.

REPLACEMENT PARTS NEEDED TO COMPLETE THESE INSTRUCTIONS

CLEANING INSTRUCTIONS:

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

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

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

2. Remove the hand-hole cover as follows: (Refer to Fig. 1)
a. Remove pressure switch box at the plumbing union and move it out of the way.
b. With an open end wrench back off the hex-nut, counterclockwise, so only two threads are

holding it. Then remove the pressure switch box and set aside.

c. With a blunt instrument, strike the hand-hole cover until its seal is broken.
d. Remove the hex-nut from the remaining two threads, slide off the washer and channel yoke

do not allow the hand-hole cover to drop inside.

e. Remove the hand-hole cover by turning it so that it will pass through the opening. Remove

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

23

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.

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

7. Without the use of gasket compound, re-install the hand hole cover using a new gasket and
dynaseal 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 hand hole
cover, relieve the pressure in the boiler and retighten the hex nut.

8. Clean the water gauge glass as follows:
a. Move the heat and power switch to their off positions. This will allow the boiler to empty.
b. Unscrew the fittings from both valves and slide them toward the center of the gauge glass.

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

c. Remove and discard the two rubber and brass washers. Slip off the two valve fittings and

clean the water gauge glass.

d. Reassemble by reversing the above steps with new rubber and brass washers (see image

below).

24

Application Instructions for Total Concept Descaler Cleaning of the Boiler

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.

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.

Figure 1

1. Energize boiler and fill to operating level.

Figure 2

2. Energize heating circuit to pre-heat unit.
Figure 3

Figure 4

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

S-2299

Size: Case of 4 -1 Gallon Bottles / Part No. 20-0307 or 1-1 Gallon Bottle / Part No. 20-0307X

APPLICATION INSTRUCTIONS

25

Application Instructions for Total Concept Descaler Cleaning of the Boiler

Figure 5

4. Remove the shipping cap, replace it with the
pouring cap. Cut the tip of the pouring cap at
the first notch to a 45

o

angle.

5. Install the tubing firmly over the tip of the
pouring cap.

Figure 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.

Figure 7

8. Feed the tubing through the access port in the
boiler compartment (figure 8).

S-2299

Figure 8

NOTE: A minimum of 12” must be inserted.

Figure 9

9. Tilt the container, pour the contents into the

unit.

10. When empty, refill the container with hot tap

water 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.

11. After rinsing the container, place tubing

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

12. DO NOT ENERGIZE HEATERS. Allow 2

hours for cleaning.

13. After time has elapsed, drain the boiler.

14. Refill the boiler and drain. Repeat this step

twice.

15. Bring the boiler to temperature and cycle

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

16. Boiler is now ready for use.

Size: Case of 4 -1 Gallon Bottles / Part No. 20-0307 or 1-1 Gallon Bottle / Part No. 20-0307X

APPLICATION INSTRUCTIONS