Market Forge Industries M24G100A-4SP User manual

0
OWNER’S MANUAL
Gas Operated Boilers
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 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]
[email protected]m, 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.

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
INSTALLATION INSTRUCTIONS
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
size of the waste line accordingly.
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.

6
INSTALLATION INSTRUCTIONS
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).
LOWER DEFLECTOR
200K Boiler
98-3972
300K Boiler
98-3976
UPPER DEFLECTOR
200K Boiler
94-5115
300K Boiler
94-5095

7
OPERATING INSTRUCTIONS
CONTROL PANEL:
MODELS: • M24G100A - 4SP
• M24G200A - 4SP
•M36G100A - 4SP
• M36G200A - 4SP
• M36G300A - 4SP
OPERATING THE STEAM GENERATOR:
OPERATING INSTRUCTIONS
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.)

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
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:
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 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 Trouble-
Shooting Guide in this manual.
f) After making adjustments, replace cover on pressure switch box and screw.

10
GENERAL TROUBLE SHOOTING
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.

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
WATER CONTROL BOARD 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

13
ILLUSTRATED PARTS LIST
BOILER BASE - 24”
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

14
ILLUSTRATED PARTS LIST
PRESSURE SWITCH BOX, WITHOUT COVER
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

15
ILLUSTRATED PARTS LIST
CONTROL BOX ASEMBLY, WITH & WITHOUT COVER
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

16
ILLUSTRATED PARTS LIST
PLUMBING, LEFT SIDE GAS BOILER –24”
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

17
ILLUSTRATED PARTS LIST
FRONT VIEW GAS BOILER, 200K –24”
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

18
ILLUSTRATED PARTS LIST
GAS TRAIN, 200K GAS BOILER
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

19
ILLUSTRATED PARTS LIST
GAS TRAIN, 200K GAS BOILER
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