Market Forge Industries M24G100A-4SP, Owner'S Manual

Page 1: ...TALLING OR SERVICING THIS EQUIPMENT Form Number S 2404 REV F 05 13 Printed in USA 35 Garvey Street Everett MA 02149 Telephone 617 387 4100 866 698 3188 Fax 617 387 4456 800 227 2659 custserv mfii com 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...

Page 2: ...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 I...

Page 3: ...e 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 provid...

Page 4: ...om 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 ...

Page 5: ...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...

Page 6: ...lation 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 ...

Page 7: ...nings 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 LOWER DEFLECTOR 200K Boiler 98 3972 300K Boiler 98 3976 UPPER DEFLECTOR 200K Boiler 94 51...

Page 8: ...TH 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...

Page 9: ...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 ...

Page 10: ...w 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 ...

Page 11: ...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 press...

Page 12: ...me 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 ...

Page 13: ...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 Co...

Page 14: ...embly 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 94 501...

Page 15: ...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 ...

Page 16: ...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 ...

Page 17: ...ly 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 ...

Page 18: ...00K 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 ...

Page 19: ... 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 ...

Page 20: ...ON 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 ...

Page 21: ...20 ELECTRICAL INFORMATION Wiring Diagram for New Generation Boilers 100K 200K 300K BTU ...

Page 22: ...21 ELECTRICAL INFORMATION Schematic Diagram for New Generation Boilers 100K 200K 300K BTU ...

Page 23: ...ies are available to establish a suitable schedule for TOTAL CONCEPT cleaning and descaler replacement REPLACEMENT PARTS NEEDED TO COMPLETE THESE INSTRUCTIONS 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 INSTRUCTIO...

Page 24: ...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...

Page 25: ...00 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...

Page 26: ...cess 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 ri...