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