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
Printed in U.S.A.
REV: D
07/06
An Employee Owned Company
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35 Garvey Street Everett MA 02149
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Tel: (617) 387-4100 Fax: (617) 387-4456 Outside MA Fax: (800) 227-2659
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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 ac-
quaint 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.
INTRODUCTION:
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.
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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 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 deflector 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-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.
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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 mod-
erate 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.
d) Natural gas units are equipped with a pressure regulator factory adjusted to give 4” (102mm) water col-
umn manifold pressure.
e) Propane gas units are equipped with a pressure regulator, factory adjusted, to give 10” (254mm) water
column manifold pressure.
f) 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.
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INSTALLATION INSTRUCTIONS
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/cm2) and a min of 25PSI (1.8
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/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 gal. (19 liters) per minute. DO NOT MAKE
SOLID CONNECTION TO FLOOR DRAIN.
EC
ST
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.
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 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.
CAUTION: Before connecting water to this unit, water sup-
ply 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.
NOTE:
PVC & CPVC PIPE ARE NOT ACCEPTABLE
MATERIALS FOR DRAINS.
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 size of the waste line accordingly.
WARNING:
DO NOT UNDER ANY CIRCUMSTANCE
CONNECT THE EXHAUST DRAIN LINE
DIRECTLY TO A SEWER LINE.
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INSTALLATION INSTRUCTIONS
LOWER DEFLECTOR ASSEMBLY
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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.)
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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 noti-
fied.
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.
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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.
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 ad-
justed.
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:
WARNING: Because power must be on to adjust pressure switches, be sure to protect against electrical shock.
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 condensor 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 opera-
tion, adjustment is correct. If proper adjustment cannot be made consult Trouble-Shooting Guide in this
manual.
f) After making adjustments, replace cover on pressure switch box and screw.
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GENERAL TROUBL-SHOOTING
TROUBLE
POSSIBLE CAUSE
REMEDY
Pilot will not ignite or does not hold. 1. Gas not reaching unit.
1. Check to make sure gas is on
and gas line is purged of air.
2. Main “gas cock knob” not in
ON position.
2. Depress and turn “main gas
cock” to pilot position - (refer to
lighting instructions).
3. Air pocket or clog in gas line.
4. Defective wiring or poor con-
nection at pilotstat power unit.
3. Purge or blow out gas line.
4. Check - replace or tighten.
5. Defective switching across
either the water level control or 5. Make continuity check - replace
pressure switches.
units that are defective.
6. Defective gas valve.
6. Replace gas valve.
Water enters boiler very slowly.
1. Clogged strainer screen on
1. Clean or replace strainer
screen. (P/N 08-4871).
water fill solenoid valve
2. Debris or lime accumulation on 2. Clean valve seat
seat of water fill valve.
Boiler overfills with water
1. Probes scaled.
1. Clean.
2. Water supply valve fails to
close.
2. Clean valve seat or replace
valve.
3. Defective water level control.
3. Follow the test procedure on
page 11. Replace if defective.
Main Burners will not ignite or will
not remain lighted.
1. No water in boiler.
1. Check to be sure water switch
is on. Check to be sure main
water supply is on and the elec-
trical supply to unit is on.
2. Main gas cock or supply line
not open.
3. Pressure switch set too low.
4. No voltage to gas valve.
5. Gas valve defective.
2. Open.
3. Reset - if continuity check
shows to be defective - replace.
4. Check main fuse.
5. Replace.
Boiler fails to build up any pressure 1. Check to see that main gas is
1. Turn on.
when the water is at the correct
level and the fuel switch is turned
on.
turned on.
2. Turn to burners “on”.
2. Check to see that gas valve is
in burners “on” position.
3. Check for voltage thru right
side of control board, replace if
defective.
3. Current flow is broken at water
level control (ascertain with
continuity check).
4. Re-adjust to proper setting -
refer to instruction for re-adjust-
ment, replace if defective.
4. Current flow is broken at pres-
sure control or high limit control
switches (ascertain with conti-
nuity check).
Water level in gauge glass
fluctuates up and down.
1. Top shutoff valve on water
gauge glass is closed.
1. Open.
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GENERAL TROUBL-SHOOTING
TROUBLE
POSSIBLE CAUSE
REMEDY
Boiler fails to reach full operating
pressure of 5 lbs. or 15 lbs.
1. Pressure gauge reads inaccu-
rately.
1. Replace.
2. Follow instructions for readjust-
ing. (page 10)
2. Pressure control and high limit
control switches are out of ad-
justment.
3. Purge manually or replace.
4. Adjust water level control
- check water feed valve for
sticking - clean or replace.
3. Safety valve not seating prop-
erly.
4. Water level too high.
5. Replace.
5. Air vent not venting properly.
6. See instructions on gas adjust-
ments. (page 5)
6. Insufficient flames on burners
or improper gas supply.
Boiler fails to cut off after reaching
operating pressure.
1. Pressure switch set too high or 1. Adjust or replace if defective.
defective.
2. Replace gas valve.
2. Gas valve fails to cut off gas
supply when demands of pres-
sure switch have been met.
Safety valve blows off prematurely. 1. Pressure set too high.
1. Readjust pressure control.
(page 10)
2. Pressure gauge reads incor-
rectly.
2. Replace.
3. Lime or debris on seat of valve 3. Purge or replace.
Boiler builds up to pressure, shuts
down, fails to come back on.
1. 1. High limit switch set to low
or operating pressure control
switch set too high.
1. 1. Follow instructions for read-
justing, see (page 10) Replace
if defective.
Water does not enter boiler.
1. Main water supply off.
2. Power not reaching unit.
3. Probes Dirty.
1. Turn on.
2. Check main fuse or circuit.
3. Remove & Clean
4. Water level control board defec- 4. See page 11 for test procedure.
tive.
5. If Voltage is verified at solenoid
5. Solenoid valve defective
coil, but fails to open, replace
solenoid.
Cold water condenser does not
function.
1. Main water supply off.
2. Thermostat defective.
3. Loose coil nut.
1. Turn on.
2. Replace if defective.
3. Tighten coil nut.
4. Solenoid coil not energized.
4. Check coil for continuity, if open
replace.
Air vent leaking.
1. Not closing.
1. Replace.
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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 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 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.
» ‘LED l’ should turn off after a 10 sec- » Use V-O-M to verify that there is pow-
ond delay.
er at the ‘LO LlTE(NC)’terminal and no
power at the ‘HTR(NO)’ terminal.
» Alligator clip type test jumpers (2 sets » Use V-O-M to verify that there is no
min.).
power at the ‘FW (NO)’ terminal.
» Remove the jumper wires from the
‘RESET’ terminals.
Turn Off Power to Control:
» Use V-O-M to verify there is no power
at terminals L 1 & L2.
» Remove jumper from ‘FW HIGH’ and
» ‘LED 2’ should turn on.
» ‘GND’ terminals. . ‘LED l’ 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.
» 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 Test Primary Low Water Function:
will need to find the source and turn » Connect jumper wire to ‘LW(1) and
it off.
» Use V-O-M to verify that there is pow-
er at the ‘FW(NO)’ terminal.
» Connect jumper wire to ‘RESET’ ter-
minals.
‘GND’ terminals.
» Remove jumper wire from ‘LW(2)’ and
‘GND’ terminals.
Remove Wires from Probe and Relay » ‘LED 3’ should turn on.
Switch Terminals:
» DO NOT remove wires from L 1 & L2
terminals.
» ‘LED 2’ should turn off after a 3 second
delay.
» Remove jumper wire from ‘LW(1)’ and
‘GND’ terminals.
» USE V-O-M to verify that there is pow-
er at the ‘LO LlTE(NC)’ terminal and
no power at the ‘HTR(NO)’ terminal.
» ‘LED 3’ should turn off after a 3 second
» Tag wires and remove from probe and
relay contact terminals including ‘GND’
terminal.
delay.
» Connect jumper wire to ‘LW(1)’ and
‘GND’ terminals.
» Connect jumper wire from ‘LW(2)’ and
‘GND’ terminals.
» Tag and remove wires from ‘RESET’
terminals.
» ‘LED 3’ should turn on.
» ‘LED 2’ should remain off.
» Connect jumper wire to both ’RESET’
terminals.
Turn Power On to Terminals L 1 & L2:
» ‘LED l’ should turn on.
IF ANY OF THE FUNCTIONS DO
NOT WORK, REPLACE THE
BOARD!
IMPORTANT:
Jumper wire between ‘LW(1) and ‘GND’
terminals must remain in place to test
secondary low water function.
» ‘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
IF ALL FUNCTIONS WORK,
TROUBLE-SHOOTING OTHER
COMPONENTS WILL BE
REQUIRED!
Test Secondary Low Water Function:
» Connect jumper wire to ‘LW(2)’ and
‘GND’ terminals.
Test Feedwater Function:
» Connect jumper wire to ‘FW HIGH’
and ‘GND’ terminals.
» ‘LED 2’ should remain off.
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ILLUSTRATED PARTS LIST
24” Boiler Base Cabinet Shown
ITEM NO.
PART
NO.
DESCRIPTION
1
1
91-8892
91-8938
91-8893
91-2713
98-0593
91-8936
08-5894
91-5795
94-5007
94-5006
10-0631
08-5206
08-5211
08-5208
10-0326
98-3968
98-3978
98-3991
98-3994
98-4010
98-3995
98-3996
Flue Outer, 24” Front
Flue Outer, 36” Front
Flue Outer, 24” Back
Flue Outer, 36” Back
2
2
3
Flue Inner Assy, 100 & 200k Boiler
Flue Inner Assy, 300k Boiler
Market Forge Nameplate Logo
Handle, Front
3
4
5
6
Panel, Front Assy, 24”
Panel, Front Assy, 36”
Leg, 6”
6
7
7
Leg, 8”
7
Leg, 10”
7
Leg, Flanged 6”
7
Caster, 5”
8
Trim, Edge
9
Glass
10
11
11
12
12
Gasket, Adhesive
Panel, Side (Set of 2 Panels)
Panel, Side (Single Panel)
Panel, Rear Assy, 24”
Panel, Rear Assy, 36”
11
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ILLUSTRATED PARTS LIST
Pressure Switch Box, without Cover
ITEM NO.
PART
NO.
DESCRIPTION
1
2
3
4
5
6
94-5064
10-8410
10-8411
98-3875
08-7933
10-4804
Box, Pressure Switch
Pressure Switch, Hi-Limit
Pressure Switch, Operating
Switch, Drain By-Pass
Manifold, Pressure Switches
Pressure Gauge
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ILLUSTRATED PARTS LIST
11
Control Box Assembly, with and without Cover
ITEM NO.
PART
NO.
DESCRIPTION
1
2
08-6549
94-5127
10-5052
08-6450
98-1680
94-5022
08-6472
08-6475
98-3877
94-5003
94-5066
94-5069
Switch, Power
Switch, Manual Reset
Light, Red
3
4
Transformer, 120-240V
5
Board, Water Level Control
Ignition Module
Relay Tube
6
7
8
Relay Base
9
Relay Bracket
Artwork, Control Box
Cover
10
11
12
Terminal Strip
13
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ILLUSTRATED PARTS LIST
15
Plumbing, Left Side Gas Boiler, 24”
ITEM NO.
PART
NO.
DESCRIPTION
1
2
10-0239
10-4137
91-6927
10-7955
10-1058
10-1311
08-4822
08-7959
98-3894
98-3914
98-1401
10-0287
10-4137
08-7974
98-3892
Hose, Drain
Clamp Hose
3
Box Drain Assy
Valve, Safety, 15 PSI
4
5
Valve, Cold Water Condenser, 120V
Valve, Drain, 120V
Valve, Boiler Feed
Hose, Condenser
Copper, Nozzle
6
7
8
9
10
11
12
13
14
15
Comp Fitting
Valve, Check
Hose, Drain
Clamp, Hose
Clamp, Hose
Condenser Thermostat
14
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ILLUSTRATED PARTS LIST
13
Front View Gas Boiler, 24”, 200K
ITEM NO.
PART
NO.
DESCRIPTION
1
2
08-4900
94-5023
94-5033
94-5034
10-3661
10-1311
91-5112
10-7955
10-4556
08-4991
94-5065
94-5010
94-5128
08-7970
Water Inlet, Manual Valve
Gas Valve
3
Gas Manifold, 100K & 200K Boilers
Gas Manifold, 300K Boilers
Drain Valve, Maunal
3
4
5
Drain Valve, Automatic
Probe Plate Assy
6
7
Safety Valve
8
Air Vent
9
Tee, 3/4”, Side Outlet
Cover, Pressure Switch Box
Label, Pressure Switch Box
Gas Valve, 120V, Propane Kit
Hose, Water, 20”
10
11
12
13
15
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ILLUSTRATED PARTS LIST
Gas Train, 200K BTU Boiler Shown
ITEM NO.
PART
NO.
DESCRIPTION
1
2
98-3923
10-7955
91-7031
08-4413
08-6399
08-6398
08-6364
91-8810
08-4415
10-2414
10-2310
91-8811
10-4754
90-0039
10-2728
98-3928
98-3936
Vent, Bleeder
Valve, Safety, 15 PSI
Probe Plate
3
4
Gasket, Probe Plate
Probe, Lowest Probe
Probe
5
Kit; P/N: 91-5112
6
}
7
Probe
8
Cover Hand Hole
Gasket Hand Hole
Nut
9
10
11
12
13
14
15
16
17
Washer
Yoke
Glass, Sight Gauge, 6”
Rubber & Brass Washer Set
Kit, Complete Includes: Valves, Glass
Elbow 1/2”, Side Outlet
Stud, 1/4-20
16
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ILLUSTRATED PARTS LIST
Gas Train, 200K Boiler Shown
ITEM NO.
PART
NO.
DESCRIPTION
1
2
3
4
5
6
7
8
8
9
08-7832
10-1154
98-3890
94-5099
94-5129
94-5046
94-5052
08-7119
08-7120
08-7118
Tube, Flex, Gas Line
Compression Coupling
Pilot Tube
Spark Pilot and Igniter
Pilot Orifice, Prop.
Burner
Pilot Brkt
Orifice, Natural Gas (Brass #30)
Orifice, Propane (#45 Black)
Orifice Hood
17
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ELECTRICAL INFORMATION
Wiring Diagram for New Generation Boilers - 100K, 200K and 300K BTU
D
98 - 1129 F
18
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ELECTRICAL INFORMATION
Schematic Diagram for New Generation Boilers - 100K, 200K and 300K BTU
D
98 - 1129 F
19
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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 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 condi-
tions. 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 clean-
ing and descaler replacement.
REPLACEMENT PARTS NEEDED TO COMPLETE THESE INSTRUCTIONS
NUMBER REQUIRED
PART NO.
08-4415
90-0039
08-4413
08-0049
10-1135
1 Hand-hole Cover Gasket
1 Set of Rubber & Brass Washers
1 Probe Plate Gasket (Gas Only)
1 Market Forge Cathodic Descaler (all boilers) new style
1 Dynaseal Washer
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.
Fig. 1.
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.
20
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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 dy-
naseal are clean and smooth.
Fig. 2.
Fig. 3.
6. To protect against further scale and corrosion remove the old cathodic descaler. Install a New Market Forge
Cathodic Descaler. See fig. 2 or 3, page 43.
7. Without the use of gasket compound, re-install the handhole 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 handhole 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 guage 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 wa-
ter gauge glass.
d) Reassemble by reversing the above steps with new rubber and brass washers . (see fig. 4)
Fig. 4.
21
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APPLICATION INSTRUCTIONS
S-2299
APPLICATION INSTRUCTIONS FOR TOTAL CONCEPT CLEANING OF BOILER
SIZE: 1 Gallon PART NUMBER: 20 - 0307
Fig. 2
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).
2. Energize heating circuit to pre-heat unit.
For manual boilers, make certain drain valve is tightly
closed.
Fig. 3
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/des-
caler to boiler chamber during maintenance.
On Market Forged boilers manufactured before 8/84; ac-
cess 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; in-
cluding all warning and cautionary statements.
Fig. 1
Fig. 4
3. AUTOMATIC - After unit is pre-heated, cycle the pow-
er switch to the OFF position then immediately back
to the ON position.
1. Energize boiler and fill to operating level.
22
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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 8. Feed the tubing through the access port in the boiler
cap. Cut the tip of the pouring cap at the first notch to
compartment.
a 45o angle.
NOTE: A minimum of 12” must be inserted.
5. Install the tubing firmly over the tip of the pouring
cap.
Fig. 9
Fig. 6
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.
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.
11. After rinsing the container, place tubing inside the
bottle, cover with shipping cap, dispose of properly.
DO NOT REUSE CONTAINER.
CAUTION: HE7DER PIPE &ACCESS PLUGARE HOT.
Fig. 7
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.
23
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