Market Forge Industries M36G200A-4SP manual

GAS OPERATED BOILER INST ALLA TION, OPERA TING, MAINTENANCE & P ARTS MANUAL MODELS: • M24G100A-4SP • M24G200A-4SP • M36G100A-4SP • M36G200A-4SP • M36G300A-4SP W ARNING: IMPROPER INST ALLA TION, ADJUSTMENT , AL TERA TION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJUR Y OR DEA TH. READ THE INST ALLA TION, OPERA TION AND MAINTE[...]

T ABLE OF CONTENTS INTRODUCTION .......................................................................................................................................ii TO THE KITCHEN MANAGER ......................................................................................................... ii INTRODUCTION ...................................[...]

ii INTRODUCTION TO THE KITCHEN MANAGER: Read this manual carefully and in its entirety . Contact Market Forge Ind., Inc. for clarication if necessary . Protect your kitchen personnel from scalding and other serious injury by providing training programs to ac- quaint all equipment operators with the correct and safe methods of operation. Operator[...]

1 INST ALLA TION INSTRUCTIONS GAS OPERA TED 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 inst[...]

2 INST ALLA TION INSTRUCTIONS *GAS SERVICE CONNECTIONS: 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-Of f Front Panel. If this plate is marked for a different gas than that supplied, notify your dealer immediately . Install an external gas supply[...]

3 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 2 ) and a min of 25PSI ( 1.8 kgcm 2 ) water pressure. CAUTION: FIL T[...]

4 INST ALLA TION INSTRUCTIONS LOWER DEFLECTOR ASSEMBL Y[...]

5 OPERA TING INSTRUCTIONS MODELS: • M24G100A - 4SP • M24G200A - 4SP • M36G100A - 4SP • M36G200A - 4SP • M36G300A - 4SP Control Panel OPERA TING INSTRUCTIONS STEAM GENERA TORS FIRST CHECK TO BE SURE THA T : A. W A TER SWITCH IS IN THE OFF POSITION. B. W A TER SUPPL Y V AL VE IS OPEN. C. ELECTRICITY IS CONNECTED TO ALL UNITS. D. THA T THE G[...]

6 OPERA TING 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 se[...]

7 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 ). Check boiler pressure gauge. If gauge indicates 5 to 7 PS[...]

8 GENERAL TROUBL-SHOOTING TROUBLE POSSIBLE CAUSE REMEDY Pilot will not ignite or does not hold. Gas not reaching unit. Main “gas cock knob” not in ON position. Air pocket or clog in gas line. Defective wiring or poor con- nection at pilotstat power unit. Defective switching across either the water level control or pressure switches. Defective g[...]

9 GENERAL TROUBL-SHOOTING TROUBLE POSSIBLE CAUSE REMEDY Boiler fails to reach full operating pressure of 5 lbs. or 15 lbs. Pressure gauge reads inaccu- rately . Pressure control and high limit control switches are out of ad- justment. Safety valve not seating prop- erly . W ater level too high. Air vent not venting properly . Insufcient ames [...]

10 TESTING PROCEDURE W A TER CONTROL BOARD TESTING PROCEDURE This test procedure is to be used to determine if the control is working properly . It is not intended to de- termine why the control may have failed. If testing shows that the control is operating properly , check all probe and solenoid wiring and the condi- tion of the electrodes in the[...]

1 1 ILLUSTRA TED P ARTS LIST 24” Boiler Base Cabinet Shown ITEM NO. P ART NO. DESCRIPTION 1 91-8892 Flue Outer , 24” Front 1 91-8938 Flue Outer , 36” Front 2 91-8893 Flue Outer , 24” Back 2 91-2713 Flue Outer , 36” Back 3 98-0593 Flue Inner Assy , 100 & 200k Boiler 3 91-8936 Flue Inner Assy , 300k Boiler 4 08-5894 Market Forge Namepla[...]

12 ILLUSTRA TED P ARTS LIST Pressure Switch Box, without Cover ITEM NO. P ART NO. DESCRIPTION 1 94-5064 Box, Pressure Switch 2 10-8410 Pressure Switch, Hi-Limit 3 10-841 1 Pressure Switch, Operating 4 98-3875 Switch, Drain By-Pass 5 08-7933 Manifold, Pressure Switches 6 10-4804 Pressure Gauge Pressure Switch Box[...]

13 ILLUSTRA TED P ARTS LIST Control Box Assembly , with and without Cover ITEM NO. P ART NO. DESCRIPTION 1 08-6549 Switch, Power 2 94-5127 Switch, Manual Reset 3 10-5052 Light, Red 4 08-6450 T ransformer , 120-240V 5 98-1680 Board, W ater Level Control 6 94-5022 Ignition Module 7 08-6472 Relay T ube 8 08-6475 Relay Base 9 98-3877 Relay Bracket 10 9[...]

14 ILLUSTRA TED P ARTS LIST Plumbing, Left Side Gas Boiler , 24” ITEM NO. P ART NO. DESCRIPTION 1 10-0239 Hose, Drain 2 10-4137 Clamp Hose 3 91-6927 Box Drain Assy 4 10-7955 V alve, Safety , 15 PSI 5 10-1058 V alve, Cold Water Condenser , 120V 6 10-131 1 V alve, Drain, 120V 7 08-4822 V alve, Boiler Feed 8 08-7959 Hose, Condenser 9 98-3894 Copper [...]

15 ILLUSTRA TED P ARTS LIST Front View Gas Boiler , 24”, 200K ITEM NO. P ART NO. DESCRIPTION 1 08-4900 W ater Inlet, Manual V alve 2 94-5023 Gas V alve 3 94-5033 Gas Manifold, 100K & 200K Boilers 3 94-5034 Gas Manifold, 300K Boilers 4 10-3661 Drain V alve, Maunal 5 10-131 1 Drain V alve, Automatic 6 91-51 12 Probe Plate Assy 7 10-7955 Safety [...]

16 ILLUSTRA TED P ARTS LIST Gas T rain, 200K BTU Boiler Shown ITEM NO. P ART NO. DESCRIPTION 1 98-3923 V ent, Bleeder 2 10-7955 V alve, Safety , 15 PSI 3 91-7031 Probe Plate 4 08-4413 Gasket, Probe Plate 5 08-6399 Probe, Lowest Probe Kit; P/N: 91-51 12 6 08-6398 Probe 7 08-6364 Probe 8 91-8810 Cover Hand Hole 9 08-4415 Gasket Hand Hole 10 10-2414 N[...]

17 ILLUSTRA TED P ARTS LIST 200K BTU Boiler Shown Gas T rain, 200K Boiler Shown ITEM NO. P ART NO. DESCRIPTION 1 08-7832 T ube, Flex, Gas Line 2 10-1 154 Compression Coupling 3 98-3890 Pilot T ube 4 94-5099 Spark Pilot and Igniter 5 94-5129 Pilot Orice, Prop. 6 94-5046 Burner 7 94-5052 Pilot Brkt 8 08-71 19 Orice, Natural Gas (Brass #30) 8 08[...]

18 ELECTRICAL INFORMA TION D 98 - 1 129 F Wiring Diagram for New Generation Boilers - 100K, 200K and 300K BTU[...]

19 ELECTRICAL INFORMA TION Schematic Diagram for New Generation Boilers - 100K, 200K and 300K BTU D 98 - 1 129 F[...]

20 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 loca- tion. Market Forge is recommending a cleaning schedule that will keep your equipment in p[...]

21 MAINTENANCE Clean rust, scale and lime deposits from the inside of the boiler with a wire brush. After removing all debris, ush out with clean water through the hand-hole and drain . Clean the hand-hole cover with a wire brush and wash. Be sure the areas that contact the gasket and dy- naseal are clean and smooth. T o protect against further [...]

22 APPLICA TION INSTRUCTIONS S - 2 2 9 9 APPLICA TION INSTRUCTIONS FOR TOT AL CONCEPT CLEANING OF BOILER SIZE: 1 Gallon P ART 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. T o determine which type you have, open cabinet doors and you will see a c[...]

23 APPLICA TION INSTRUCTIONS S - 2 2 9 9 APPLICA TION INSTRUCTIONS FOR TOT AL CONCEPT CLEANING OF BOILER SIZE: 1 Gallon P ART NUMBER: 20 - 0307 Fig. 5 4. Remove the shipping cap, replace it with the pouring cap. Cut the tip of the pouring cap at the rst notch to a 45 o angle. 5. Install the tubing rmly over the tip of the pouring cap. Fig. 6 [...]