Transcript
MODULAR GAS STEAM SUPPLY GENERATORS Parts & Service Manual
5033A
Printed in U.S.A. 4/75
Everett Ma. 02149 Area Code 617 387-4100
TABLE OF CONTENTS
Subject
Code No.
Page
HOW TO USE THIS MANUAL
5023
3
BOILER STARTING INSTRUCTIONS
5023
3
170,000 BTU GAS BOILER - ASSEMBLY
5024
4
170 000 BTU GAS BOILER -PARTS LIST
5024
4
250,000 BTU GAS BOILER - ASSEMBLY
5026
5
250,000 BTU GAS BOILER - PARTS LIST
5026
5
LIGHTING INSTRUCTIONS
5028
6
ADJUSTING THE BURNERS
5028
6
CONTROL BOX ASSEMBLY - MANUAL BLOWDOWN
5150
7
CONTROL BOX.ASSEMBLY - AUTOMATIC BLOWDOWN
5151
8
WATER LEVEL CONTROL
5008
9
WATER LEVEL CONTROL ADJUSTMENTS
5009
10
SERVICING THE SOLENOID WATER FEEDERS
5009
10
PRESSURE REDUCING VALVE
5010
11
24 INCH CABINET
5011
12
36 INCH CABINET
5012
13
WIRING DIAGRAMS
5013
14
WIRING DIAGRAMS
5014
15
TROUBLE-SHOOTING GUIDE
5029
16
TROUBLE-SHOOTING GUIDE
5030
17
TROUBLE-SHOOTING GUIDE
5031
18
SETTING OF BOILER CONTROL PRESSURE SWITCHES
5032
19
COLD WATER CONDENSER ADJUSTMENT
5032
19
5035
Market Forge, in the interest of both costs and efficiency to the purchasers of its equipment, has designed these boilers with the latest type automatic controls in order to make it easier for the operator to use and maintain this equipment. In addition, standard components are utilized on all models of boiler equipment unless variances in size or capacity dictate a divergence from this policy for more efficiency in operation. This parts and service manual is written and illustrated to cover all boiler equipment that uses gas as a source of power other than those which have been custom designed under special order.
HOW TO USE THIS MANUAL The exploded view drawings of components are aids to the identification, disassembly and assembly of parts. The parts l istings provide 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, which will indicate to Market Forge Service Division the type of boiler with which you are equipped. This information can be found on the nameplate attached to the boiler frame.
OPERATING INSTRUCTIONS FOR GAS BOILERS
Explanation of how the control system works on manual and automatic gas boilers. With the boiler filled with water to its proper level and the fuel switch turned to its on position, the solenoid in the gas valve will be activated allowing gas to flow to main burner which will be ignited by the pilot. When the boiler builds up to its set pressure, the pressure switch on the left side of the control box opens. This will open up the circuit to the solenoid coil in the gas valve which, in turn, will stop the flow of main gas to the burners. As the pressure in the boiler drops off the pressure control switch will again come into operation and complete the circuit and build the boiler back up to its set pressure. When the operator wishes to stop all generation he need only to place the fuel switch to the off position.
5023
170,000 BTU GAS BOILER
AUTOMATIC BOILERS ONLY
30
SUPPLIED WHEN BOTH 5 &15STEAM SUPPLY IS NEEDED
MODEL: M24G1A or M36G1A SPARE PARTS LIST GAS STEAM GENERATORS 170,000 BTU'S ITEM 1 2 3 4 5 6 7 8 9 10
11
11
11
12 13 14 15 16 17 18
QTY.
PART NUMBER
1 10-1146 1 10-5869 1 10-4940 1 90 - 0039 1 10-2310 1 10-2414 1 90 - 5492 1 10-2661 1 90 - 5495 1 10-1135 1 10-2118 WATER LEVEL CONTROL ASSEMBLIES WATTS 1 90 - 8929 2 10-5714 1 10-5208 1 10-5209 1 90 - 5249 1 91 - 5382 1 91 - 6222 McDONNELL MILLER 1 09 - 4887 1 08-1409
DESCRIPTION WATER GAUGE GLASS 51/2" WATER GAUGE GLASS 11" WATER GAUGE ASSY. RUBBER & BRASS WASHERS 5/8" HEX NUT ( hand hole cover) 5/8" WASHER ( hand hole cover ) CHANNEL, YOKE ( hand hole cover ) HAND HOLE GASKET HAND HOLE COVER DYNA - SEAL WASHER BOLT ( hand hole cover)
COMPLETE FLOAT ASSEMBLY MICRO SWITCHES FLOAT BALL GASKET HEAD BELLOWS LINK & ROD ASSY. KIT, ADAPTOR - GASKETS HEAVY DUTY GASKET KIT REWORKED FLOAT ASSEMBLY GASKET, RING
8
09 - 3436
1
PROBE SYSTEM 91 - 6287
HX. HD.SCW.10-24 x 1/2" lg.
1 1 1 1 1 1 1 1 1
91 -5112 08 - 6328 08 - 6329 08 - 6407 08 - 6364 08 - 6365 91 - 6286 08 - 4405 91 - 7031
KIT, FIELD REPLACEMENT, (3) PROBES, PLATE & GASKET LIQUID LEVEL CONTROL BD. ( 120 volt LIQUID LEVEL CONTROL BD. ( 240 volt) LIQUID LEVEL CONTROL BD. ( California Code ) LIQUID LEVEL PROBE ( water fill ) LIQUID LEVEL PROBE (low water level ) PROBE PLATE, WELDED GASKET FOR PROBE PLATE PROBE PLATE, WELDED, ( 3 ) PROBES
1 1 1 2 2 4 1 1 7 1 1 1 1
08-4413 08 - 6398 08 - 6399 10-2515 10-8353 09 - 3436 10-4556 10-4804 10-3250 90 - 9429 90 - 9428 10-1043 10-6472
GASKET FOR PROBE PLATE # 91 - 7031 LIQUID LEVEL PROBE, PRIMARY ( low water level ) LIQUID LEVEL PROBE, SECONDARY ( low water level) LOCKWASHER, HELI - SPRING RUBBER BOOT FOR PROBES HX. HD. SCW. 10 - 24 x 1/2" lg. AIR VENT PRESSURE GAUGE BURNER LOWER DEFLECTOR PLATE ASSY. UPPER DEFLECTOR PLATE ASSY. GAS MANIFOLD GAS VALVE ( 120volt) NATURAL 3/4" inlet X 3/4" outlet
1 1 1 1
10-7683 10-7684 10-7685 10-6465
GAS VALVE ( 120volt) PROPANE 3/4" inlet X 3/4" outlet GAS VALVE ( 240volt) NATURAL 3/4" inlet X 3/4" outlet GAS VALVE ( 240volt) PROPANE 3/4" inlet X 3/4" outlet GAS VALVE ( 120volt) NATURAL 1/2" inlet X 3/4" outlet
KIT, FIELD REPLACEMENT, PROBES, PLATE & GASKET
MODEL: M24G1A or M36G1A SPARE PARTS LIST GAS STEAM GENERATORS 170,000 BTU'S ITEM
QTY.
PART NUMBER
19
1 7
10-6487 10-2916
ADAPTER PLATE FOR PROPANE BURNER ORIFICE ( all btu's ) NATURAL
7 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
10-2921 10-5253 10-5254 91 -6154 90-1724 90-1832 10-5163 95 - 3880 90 - 7948 10-6048 90 - 5295 90 - 5294 10-3661 90-1724 90-1728 90 - 2823 90 - 2822 10 -5787 10-1311 08 - 4872 10-3015 10-1033 10-7955 10-4741
BURNER ORIFICE ( all btu's ) PROPANE PILOT BURNER & ORIFICE ( natural ) PILOT BURNER & ORIFICE ( propane ) PILOT BRACKET 2" DRAIN LINE ASSY., AUTOMATIC 2" DRAIN LINE ASSY., MANUAL OBSOLETE - NLA HAND BOX PILOT BURNER GAS LINE 24" PILOT BURNER GAS LINE 36" THERMOCOUPLE CONTROL BOX ASSY., MANUAL CONTROL BOX ASSY., AUTOMATIC DRAIN VALVE STD. 2" DRAIN LINE ASSY., AUTOMA TIC 2" DRAIN LINE ASSY., AUTOMATIC SIDE COVER PLATES RIGHT & LEFT REAR COVER PLATES 1/2" SOLENOID ASCO DRAIN VALVE 3/4" DRAIN VALVE COIL ONLY; FOR 3/4" DRAIN VALVE DRAIN VALVE REPAIR KIT ( new style ) PRESSURE REDUCING VALVE 15# SAFETY VALVE 8# SAFETY VALVE ( 5# boilers only )
20
21 22 23 24 25 26 27 28 29 30
31 32
DESCRIPTION
33 34 35 36
GAS VALVE - EXTENSION FOR PILOT PART NUMBERS 1 10-6467 ROD ADAPTER 1 10-1662 COTTER PIN 1 99-1310 GAS CONTROL KNOB 1 99-1313 EXTENSION ROD
37 38 39
MISCELLANEOUS 1 1 1
40
10-3489 10-3490 10-2844
3/4" 90 DEGREE OUTLET ELBOW 3/4" 4 WAY TEE 3/4" UNION
INSULATION 2 10-4095 MARONITE, SIDE INSULATION BOILER SHELL, FLUE PARTS & MISELLANEOUS 1 90 - 9404 BOILER REPLACEMENT SHELL 1 90 - 9323 INNER FLUE 1 90 - 8849 OUTER FLUE ( RIGHT SIDE ) 1 1 1
90 - 8850 90-1811 10-0880
OUTER FLUE ( LEFT SIDE ) ACCEPTOR FOR FLUE GAS SOLENOID VALVE (120volt)
1
91-1337
DESCALER
MODEL: M36G2A SPARE PARTS LIST GAS STEAM GENERATORS 250,000 BTU'S ITEM
QTY.
PART NUMBER
1
1 1 1 1 1 1 1 1 1 1 1
10-4754 10-5869 10-4576 90 - 0039 10-2310 10-2414 90 - 5492 10-2661 90 - 5495 10-1135 10-2118
2 3 4 5 6 7 8 9 10
DESCRIPTION WATER GAUGE GLASS 6" WATER GAUGE GLASS 11" WATER GAUGE ASSY. RUBBER & BRASS WASHERS 5/8" HEX NUT ( hand hole cover ) 5/8" WASHER ( hand hole cover ) CHANNEL, YOKE ( hand hole cover ) HAND HOLE GASKET HAND HOLE COVER DYNA - SEAL WASHER BOLT ( hand hole cover)
WATER LEVEL CONTROL ASSEMBLIES 11
1 2 1 1
WATTS 90 - 8929 10-5714 10-5208 10-5209
1 1
90 - 5249 91 - 5382
HEAD BELLOWS LINK & ROD ASSY. KIT, ADAPTOR - GASKETS
91 - 6222
HEAVY DUTY GASKET KIT
1 11
1 1 8
McDONNELL MILLER 09 - 4887 08-1409 09 - 3436
COMPLETE FLOAT ASSEMBLY MICRO SWITCHES FLOAT BALL GASKET
REWORKED FLOAT ASSEMBLY GASKET, RING HX. HD.SCW.10-24 x 1/2" Ig.
PROBE SYSTEM 11
1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 4
91 - 6287 91 -5112 08 - 6328 08 - 6329 08 - 6407 08 - 6364 08 - 6365 91 - 6286 08 - 4405 91 - 7031 08-4413 08 - 6398 08 - 6399 10-2515 10-8353 09 - 3436
KIT, FIELD REPLACEMENT, PROBES, PLATE & GASKET KIT, FIELD REPLACEMENT, (3) PROBES, PLATE & GASKET LIQUID LEVEL CONTROL BD. (120 volt) LIQUID LEVEL CONTROL BD. ( 240 volt) LIQUID LEVEL CONTROL BD. ( California Code ) LIQUID LEVEL PROBE ( water fill ) LIQUID LEVEL PROBE (low water level) PROBE PLATE, WELDED GASKET FOR PROBE PLATE PROBE PLATE, WELDED, ( 3 ) PROBES GASKET FOR PROBE PLATE # 91 - 7031 LIQUID LEVEL PROBE, PRIMARY (low water level ) LIQUID LEVEL PROBE, SECONDARY (low water level) LOCKWASHER, HELI - SPRING RUBBER BOOT FOR PROBES HX. HD. SCW. 10 - 24 x 1/2" Ig.
12
1
10-4556
AIR VENT
13 14 15 16 17
1 7 1 1 1
10-4804 10-2940 90 - 2830 90 - 2829 10-1060
PRESSURE GAUGE BURNER LOWER DEFLECTOR PLATE ASSY. UPPER DEFLECTOR PLATE ASSY. GAS MANIFOLD
MODEL: M36G2A SPARE PARTS LIST GAS STEAM GENERATORS 250,000 BTU'S ITEM
QTY.
18
1
10-6472
GAS VALVE ( 120volt) NATURAL 3/4" inlet X 3/4" outlet
1 1 1 1 7 7 1 1 1 1 1 1 1 1 1 1 1 1 1
10 -7683 10 -7684 10-7685 10-6465 10-2916 10-2921 10-5253 10-5254 91 - 3696 90-1724 90-1834 10 -5163 90 - 7888 10-6048 90 - 5295 90 - 5294 10-3661 10-7955 10-4741
GAS VALVE ( 120volt) PROPANE 3/4" inlet X 3/4" outlet GAS VALVE ( 240volt) NATURAL 3/4" inlet X 3/4" outlet GAS VALVE ( 240volt) PROPANE 3/4" inlet X 3/4" outlet GAS VALVE ( 120volt) NATURAL 1/2" inlet X 3/4" outlet BURNER ORIFICE ( all btu's ) NATURAL BURNER ORIFICE ( all btu's ) PROPANE PILOT BURNER & ORIFICE ( natural ) PILOT BURNER & ORIFICE ( propane ) PILOT BRACKET 2" DRAIN LINE ASSY., AUTOMATIC 2" DRAIN LINE ASSY., MANUAL HAND BOX PILOT BURNER GAS LINE THERMOCOUPLE CONTROL BOX ASSY., MANUAL CONTROL BOX ASSY., AUTOMATIC DRAIN VALVE STD. 15# SAFETY VALVE 8# SAFETY VALVE ( 5# boilers only )
1 1 1 1 1
90 - 2823 90 - 2822 10-5787 10-1311 08 - 4872
SIDE COVER PLATES RIGHT & LEFT REAR COVER PLATES 1/2" SOLENOID ASCO DRAIN VALVE 3/4" DRAIN VALVE COIL ONLY; 3/4" DRAIN VALVE
1 1
10 -3015 10-1033
DRAIN VALVE REPA IR KIT ( new style ) PRESSURE REDUCING VALVE
19 20
21 22 23 24 25 26 27 28 29 30
31
PART NUMBER
DESCRIPTION
GAS VALVE - EXTENSION FOR PILOT PART NUMBERS 32 33 34 35 36 37 38
1 1 1 1 MISCELLANEOUS 1 1 1 INSULATION
10-6467 10-1662 99-1310 99-1313
ROD ADAPTER COTTER PIN GAS CONTROL KNOB EXTENSION ROD
10-3489 10-3490 10-2844
3/4" 90 DEGREE OUTLET ELBOW 3/4" 4 WAY TEE 3/4" UNION
39
2
10 -4065
MARONITE, SIDE INSULATION
40
1
10-4068
MARONITE, REAR INSULATION
PARTS THAT ARE NOT SHOWN BOILER SHELL, FLUE PARTS & MISELLANEOUS 1 1 1
90-2817 90 - 4525 90 - 8849
BOILER REPLACEMENT SHELL INNER FLUE OUTER FLUE ( RIGHT SIDE )
1 1 1
90 - 8850 90 - 8066 91-1337
OUTER FLUE ( LEFT SIDE ) ACCEPTOR FOR FLUE DESCALER
LIGHTING INSTRUCTIONS FOR MANUAL GAS BOILER WITH MANUAL RESET (PILOT AND BURNERS) I. Turn gas valve to OFF. Depress knob and turn clockwise; wait 5 minutes for unburned gas to vent. While this is taking place, close boiler drain valve, open boiler inlet valve- flip water switch from Blowdown to On. 3. While boiler is filling, light match or taper. 4 Gas valve knob must be Fully and Continuously Depressed during this entire step: a. Depress knob and hold depressed while turning counter clockwise from Off to pilot and then — b. Continue Holding Knob Depressed while lighting pilot and about one minute longer to allow pilot to heat. 5 Release knob. If pilot goes out when knob is released, return knob to Off and repeat steps 1, 3, and 4. 6. Then turn gas valve knob counter clockwise until it snaps into the final stop at On. IMPORTANT: Knob will automatically return in Pilot if not snapped all the way to the On position. 7. When boiler is filled it is necessary to manually reset the. unit by flipping water switch from on to Blowdown and back to On immediately. .Had- light will come on. 8. Flip fuel switch from Off to On (This will bring gas burners on.)
ADJUSTING THE BURNERS
LIGHTING INSTRUCTIONS FOR AUTOMATIC GAS BOILE\ With MANUAL RESET - (PILOT AND BURNERS) 1. Turn gas valve to OFF. (Depress knob and turn clockwise.) Wait 5 minutes for unburned gas to vent. 2. While this is taking place, flip Water switch from Blowdown to On. Wait 3 minutes for Water to fill in boiler. 3. While boiler is filling, light match or taper. 4. Gas valve knob must be fully and continuously depressed during this entire step: a. Depress knob and hold expressed while turning) counterclockwise from Off to Pilot and then b. Continue holding knob depressed while lighting pilot and about one minute longer to allow pilot to heat. 5. Release knob. If Pilot goes out when knob is released, return knob to Off and repeat steps 1, 3, and 4. 6. Then turn gas valve knob counterclockwise until it snaps into the final stop at On. IMPORTANT: Knob will automatically return to Pilot if not snapped all the way to the On. position. 7. When boiler is filled it is necessary to manually reset the unit by flipping Water switch from On to BIowdown and back to On immediately. Red light will come on. 8. Flip Fuel switch from Off to On. (This will bring gas burners on).
The boiler has been adjusted and tested to operate with the type of gas indicated on the nameplate. However, as the nature of gas will sometimes vary in another location, minor adjustments may have to be made to establish the most efficient burner flame. In cases where manufactured or mixed gases are to be used, these adjustments will have to be made. To adjust:
1 SEE LIGHTING INSTRUCTIONS AND PROCEED TO . LIGHT BOILER 2 Look at the flame on each burner and open or close the air . shutters of each to establish the best possible adjustment. See the chart which shows typical flame characteristics for each type of gas. 3 The orifice is factory set to the correct position, if proper . adjustments cannot be made in step No. 2 Refer to the chart on Page 6 which shows the proper water column pressure for the type of gas used. Take a water column measurement at the removable plug in the center of the gas manifold.
A. IF PRESSURE IS LOW: Check your gas supply line for a restriction of some nature. If no restriction exists, check with your gas supplier to provide at least 4" of water column pressure in the gas supply line. If no restriction exists and bottled gas is being used, the tank pressure regulator should be adjusted to supply at least 11" of water column at the burner manifold. If this adjustment cannot be made to satisfaction, the gas supplier should be notified. B. IF PRESSURE IS TOO HIGH: Adjust the gas regulator on the gas valve to cut down the pres sure if natural gas is being used. If bottled gas is being used, adjust gas regulator supplied by gas supplier. If it cannot be adjusted, notify gas supplier.
NATURAL GAS
PROPANE GAS
ORIFICE DRILL SIZE
170= No. 42 250 = No. 44
170= No. 54 250 = No. 52
WATER COLUMN AT MANIFOLD
3 ½”
11"
TOO MUCH AlR
IDEAL FLAME
NOT ENOUGH AIR
5028
t
MODEL: M24G1A or M36G1A SPARE PARTS LIST GAS STEAM GENERATORS 170,000 BTU'S ITEM 1
QTY. PART NUMBER DESCRIPTION 1 10-1146 WATER GAUGE GLASS 51/2" 1 10-5869 WATER GAUGE GLASS 11" 2 1 10-4940 WATER GAUGE ASSY. 3 1 90 - 0039 RUBBER & BRASS WASHERS 4 1 10-2310 5/8" HEX NUT (hand hole cover) 5 1 10-2414 5/8" WASHER (hand hole cover) 6 1 90 - 5492 CHANNEL, YOKE (hand hole cover) 7 1 10-2661 HAND HOLE GASKET 8 1 90 - 5495 HAND HOLE COVER 9 1 10-1135 DYNA - SEAL WASHER 10 1 10-2118 BOLT (hand hole cover) WATER LEVEL CONTROL ASSEMBLIES WATTS 11 1 90 - 8929 COMPLETE FLOAT ASSEMBLY 2 10-5714 . MICRO SWITCHES 1 10-5208 FLOAT BALL 1 10-5209 GASKET 1 90 - 5249 HEAD BELLOWS LINK & ROD ASSY. McDONNELL MILLER 11 1 09 - 4887 : REWORKED FLOAT ASSEMBLY 1 08-1409 GASKET, RING 8 09 - 3436 HX. HD. SCW. 10 - 24 x 1/2" lg.( LWCO plate (4) req'd) PROBE SYSTEM 11 1 91 - 6287 KIT. FIELD REPLACEMENT. PROBES, PLATE & GASKET 1 .08-6328 LIQUID LEVEL CONTROL BD. (120 volt) 1 08 - 6329 . LIQUID LEVEL CONTROL BD. ( 240 volt) 1 08 - 6407 LIQUID LEVEL CONTROL BD. ( California Code ) 1 08 - 6364 LIQUID LEVEL PROBE ( water fill) 1 08 - 6365 LIQUID LEVEL PROBE (low water level) 1 91 - 6286 PROBE PLATE, WELDED 1 • 08 - 4405 GASKET FOR PROBE PLATE 2 10-2515 LOCKWASHER, HELI - SPRING 2 10-8353 RUBBER BOOT FOR PROBES 4 09 - 3436 HX. HD. SCW. 10 - 24 x 1/2" lg.( LWCO plate (4) req'd) 12 13 14 15 16 17 18
1 1 7 1 1 1 1 1 1 1 1
10-4556 10-4804 10-3250 90 - 9429 90 - 9428 10-1043 10-6472 10-7683 10-7684 10-7685 10-6487
AIR VENT PRESSURE GAUGE BURNER LOWER DEFLECTOR PLATE ASSY. UPPER DEFLECTOR PLATE ASSY. GAS MANIFOLD GAS VALVE (120volt) NATURAL GAS VALVE (120volt) PROPANE GAS VALVE ( 240volt) NATURAL GAS VALVE ( 240volt) PROPANE ADAPTER PLATE FOR PROPANE
M-G1A1.XLS
MODEL: M24G1A or M36G1A ITEM 19 20
21 22 23 24 25 26 27 28 29 30
31 32
33 34 35 36 37 38 39 40
QTY. PART NUMBER DESCRIPTION 7 10-2916 BURNER ORIFICE ( all btu's ) NATURAL 7 10-2921 BURNER ORIFICE ( all btu's ) PROPANE 1 10-5253 PILOT BURNER & ORIFICE ( natural) 1 10-5254 PILOT BURNER & ORIFICE ( propane ) 1 91 -6154 PILOT BRACKET 1 90-1724 2" DRAIN LINE ASSY., AUTOMATIC 1 90-1832 2" DRAIN LINE ASSY., MANUAL OBSOLETE - NLA 1 10-5163 HAND BOX 1 95 - 3880 PILOT BURNER GAS LINE 24" 1 90 - 7948 PILOT BURNER GAS LINE 36" 1 10-6048 THERMOCOUPLE 1 90 - 5295 CONTROL BOX ASSY., MANUAL 1 90 - 5294 CONTROL BOX ASSY., AUTOMATIC 1 10-3661 DRAIN VALVE STD. 1 90-1724 2" DRAIN LINE ASSY., AUTOMATIC 1 90-1728 2" DRAIN LINE ASSY., AUTOMATIC 1 90 - 2823 SIDE COVER PLATES RIGHT & LEFT 1 90 - 2822 REAR COVER PLATES 1 10-5787 1/2" SOLENOID ASCO DRAIN VALVE 1 10-1311 3/4" DRAIN VALVE 1 08 - 4872 COIL ONLY; FOR 3/4" DRAIN VALVE 1 10-3015 DRAIN VALVE REPAIR KIT (new style ) 1 10-1033 PRESSURE REDUCING VALVE 1 10-5320 15# SAFETY VALVE 1 10-4741 8# SAFETY VALVE ( 5# boilers only ) GAS VALVE - EXTENSION FOR PILOT PART NUMBERS 1 1 1
10-6467 10-1662 99-1310
1 99-1313 MISCELLANEOUS 1 10-3489 1 ' 10-3490 1 10-2844 INSULATION 2
10-4095
ROD ADAPTER COTTER PIN GAS CONTROL KNOB EXTENSION ROD 3/4" 90 DEGREE OUTLET ELBOW 3/4" 4 WAY TEE 3/4" UNION MARONITE, SIDE INSULATION
PARTS THAT ARE NOT SHOWN FLUE PARTS & MISELLANEOUS 1 1 1 1 1
90 - 9323 90 - 8849 90 - 8850 90-1811 91 -1337
INNER FLUE OUTER FLUE ( RIGHT SIDE ) OUTER FLUE ( LEFT SIDE ) ACCEPTOR FOR FLUE DESCALER
M-G1A1.XLS
250,000 BTU GAS BOILER
AUTOMATIC BOILERS ONLY 30
SUPPLIED WHEN BOTH 5& 15 STEAM SUPPLY IS NEEDED
MODEL: M36G2A SPARE PARTS LIST GAS STEAM GENERATORS 250.000 BTU'S ITEM 1 2 3 4 5 6 7 8 9 10
11
11
11
12 13 14 15 16 17 18
QTY. PART NUMBER DESCRIPTION 1 10-4754 WATER GAUGE GLASS 6" 1 10-5869 WATER GAUGE GLASS 11" 1 10-4576 WATER GAUGE ASSY. 1 90-0039 RUBBER & BRASS WASHERS 1 10-2310 5/8" HEX NUT ( hand hole cover ) 1 10-2414 5/8" WASHER ( hand hole cover ) 1 90 - 5492 CHANNEL, YOKE ( hand hole cover ) 1 10-2661 HAND HOLE GASKET 1 90 - 5495 HAND HOLE COVER 1 10-1135 DYNA - SEAL WASHER 1 10-2118 BOLT ( hand hole cover) WATER LEVEL CONTROL ASSEMBLIES WATTS 1 90 - 8929 COMPLETE FLOAT ASSEMBLY 2 10-5714 MICRO SWITCHES 1 10-5208 FLOAT BALL 1 10-5209 GASKET 1 90 - 5249 HEAD BELLOWS LINK & ROD ASSY. 1 91 - 5382 KIT, ADAPTOR - GASKETS 1 91 - 6222 HEAVY DUTY GASKET KIT McDONNELL MILLER 1 09 - 4887 REWORKED FLOAT ASSEMBLY 1 081409 GASKET, RING 8 09 - 3436 HX. HD. SCW. 10 - 24 x 1/2" lg.( LWCO plate (4) req'd) PROBE SYSTEM 1 91 - 6287 KIT, FIELD REPLACEMENT, PROBES, PLATE & GASKET 1 08-6328 LIQUID LEVEL CONTROL BD. ( 120 volt) 1 08 - 6329 LIQUID LEVEL CONTROL BD. ( 240 volt) 1 08 - 6407 LIQUID LEVEL CONTROL BD. ( California Code ) 1 08 • 6364 LIQUID LEVEL PROBE ( water fill) 1 08 - 6365 LIQUID LEVEL PROBE (low water level) 1 91 - 6286 PROBE PLATE, WELDED 1 08 - 4405 GASKET FOR PROBE PLATE 2 10-2515 LOCKWASHER, HELI - SPRING 2 10-8353 RUBBER BOOT FOR PROBES 4 09 - 3436 HX. HD. SCW. 10 - 24 x 1/2" lg.( LWCO plate (4) req'd) 1 1 7 1 1 1 1 1
10-4556 10-4804 10-2940 90 - 2830 90 - 2829 10-1060 10-6472 10-7683
AIR VENT PRESSURE GAUGE BURNER LOWER DEFLECTOR PLATE ASSY. UPPER DEFLECTOR PLATE ASSY. GAS MANIFOLD GAS VALVE ( 120volt) NATURAL GAS VALVE (120volt) PROPANE
M-G2A1 .XLS
MODEL: M36G2A ITEM
19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
QTY. PART NUMBER DESCRIPTION 1 10-7684 GAS VALVE ( 240volt) NATURAL 1 10-7685 GAS VALVE ( 240volt) PROPANE 7 10-2916 BURNER ORIFICE ( all btu's ) NATURAL 7 10-2921 BURNER ORIFICE ( all btu's ) PROPANE 1 10-5253 PILOT BURNER & ORIFICE ( natural ) 1 10-5254 PILOT BURNER & ORIFICE ( propane ) 1 91 - 3696 PILOT BRACKET 1 90-1724 2" DRAIN LINE ASSY., AUTOMATIC 1 90-1834 2" DRAIN LINE ASSY., MANUAL 1 10-5163 HAND BOX 1 90 - 7888 PILOT BURNER GAS LINE 1 10-6048 THERMOCOUPLE 1 90-5295 CONTROL BOX ASSY., MANUAL 1 90 - 5294 CONTROL BOX ASSY., AUTOMATIC 1 10-3661 DRAIN VALVE STD. 1 10-5320 15# SAFETY VALVE 1 10-4741 8# SAFETY VALVE ( 5# boilers only ) 1 90 - 2823 SIDE COVER PLATES RIGHT & LEFT 1 90 - 2822 REAR COVER PLATES 1 10-5787 1/2" SOLENOID ASCO DRAIN VALVE 1 10-1311 3/4" DRAIN VALVE 1 08 - 4872 COIL ONLY; 3/4" DRAIN VALVE 1 10-3015 DRAIN VALVE REPAIR KIT ( new style ) 1 10-1033 PRESSURE REDUCING VALVE GAS VALVE - EXTENSION FOR PILOT PART NUMBERS 1 1 1
10-6467 10-1662 99-1310
1 99-1313 MISCELLANEOUS 1 10-3489 1 10-3490 1 10-2844 INSULATION 2 1
10-4065 10-4068
ROD ADAPTER COTTER PIN GAS CONTROL KNOB EXTENSION ROD 3/4" 90 DEGREE OUTLET ELBOW 3/4" 4 WAY TEE 3/4" UNION MARONITE. SIDE INSULATION MARONITE, REAR INSULATION
PARTS THAT ARE NOT SHOWN FLUE PARTS & MISELLANEOUS 1 90 - 4525 1 90 - 8849 1 90 - 8850 1 90 - 8066 1 91-1337
INNER FLUE OUTER FLUE ( RIGHT SIDE ) OUTER FLUE ( LEFT SIDE ) ACCEPTOR FOR FLUE DESCALER
M-G2A1 .XLS
Market Forge Industries 35 GARVEY STREET, EVERETT, MA 02149
CONTROL BOX ASSEMBLY
Market Forge Industries 35 GARVEY STREET, EVERETT, MA 02149
CONTROL BOX ASSEMBLY ITEM
QTY.
PART NUMBER
1
1
90 - 9299
BOX, CONTROL - ALL BOILERS
2
1
10-6008
ASSY. PRES. CONTROL SWITCHES - OBSOLETE TO 91 - 5139
2A
1
10-8410
PRESSURE SWITCH ( high limit)
2B
1
10-8411
PRESSURE SWITCH ( operating pressure^)
3
1
10 -4653
THERMOSTAT ( drain condensate )
4
1
10-4634
TIME DELAY RELAY ( 120 volt)
5
1
10-6512
RELAY SOCKET
6
2
10-1326
HAYS SOL. VALVE ( 120 VOLT ) ( USED ON OLDER MODELS )
2
10-0865
HAYS SOL. VALVE ( 240 VOLT ) ( USED ON OLDER MODELS )
2
08 - 4821
SKINNER VALVE (120 VOLT ) CURRENT MODELS
2
08-4810
SKINNER VALVE ( 240 VOLT ) CURRENT MODELS
2
10 - 1330
REMOVABLE STRAINER FOR HAYS VALVE
2
06 - 4871
REMOVABLE STRAINER FOR SKINNER VALVE
8
1
10-6169
PILOT LIGHT
9
1
10-5008
HEAT SWITCH D.P.D.T. ( OLDER MODELS WITH WATTS FLOAT )
1
10-5484
HEAT SWITCH D.P.D.T. ( momentary ) CURRENT MODELS
40
1
10-5022
ON - OFF SWITCH S.P.S.T.
11
1
10-5184
TERMINAL STRIP
12
10-1329
REPLACEMENT COIL FOR PART NUMBER 10 - 1326
13
10-4035
DOLE SOLENOID VALVE (120 VOLT)
14
10-1109
STRAINER FOR DOLE VALVE
1
91 - 8703
CONTROL BOX ASSY. (120 VOLT W / AUTO DRAIN )
1
91 - 8704
CONTROL BOX ASSY. ( 240 VOLT W / AUTO DRAIN ) EXPORT
1
91 - 8705
CONTROL BOX ASSY. ( 120 VOLT W / MANUAL DRAIN )
1
91 - 8706
CONTROL BOX ASSY. ( 240 VOLT W / MANUAL DRAIN ) EXPORT
1
91 - 8701
C - BOX ASSY. ( 120 VOLT W / AUTO DR. ) A - PLUS W / KETTLE
1
91 - 8702
C - BOX ASSY. ( 240 VOLT W / AUTO DR. ) A - PLUS W / KETTLE
7
15
DESCRIPTION
CONTROL BOX ASSEMBLY MANUAL RESET- MANUAL BLOW-DOWN-AUTOMATIC WATER FEEDER MODULAUR UNIT ITEM NO.
PART NO.
DESCRIPTION
PART NO.
DESCRIPTION
1
90-9299
Control Box
ITEM NO. 7
10-5008
Switch - Double pole - Double throw
2
10-6008
Assy. Pres. Control switches
8
10-5022
Switch - Single pole - Single throw
for manual reset boiler
9
10-4982
Dialco Pilot light assembly
3
10-5184
Terminal Strip
10
10-1330
Strainer for Hays Valve
4
10-4634
Relay
11
101329
120 Volt Coil for Hays Valve
5
10-6512
Octal Socket
12
10 4035
Dole Solenoid Valve*
6
10-1 326
Hays Solenoid Valve
13
10-1109
Strainer for Dole Valve*
90-5284
Hays Valve Replacement Kit
14
90-5295
Complete Control Box Assembly
* These parts are no longer used on the unit. 5150
Replacement Parts Water Level Control
ITEM
DESCRIPTION
PART NO.
1 2
Complete m/f low water cut off M/F low water cut off conv.
90-8929 90-9808 Jet Only
3
Head bellows link & Rod Assy.
90-5249
4
Gasket
10-5209
5
Float Ball
10-5208
6
Nylon Adjusting Screw and Nut
10-0135 10-0136
7
Center Insulator
90-5222
8
Micro Switch
10-5714
5008
WATER LEVEL CONTROL Each boiler was operated and tested before it left our factory. However, due to vibration in transit or variations in altitude, some of the controls may need re-adjusting. The Water Level Control used by Market Forge is a float type switch with a float ball inside the boiler. The water level control is equipped with two micro-switches which turns the water supply on and off and the power supply on and off.
HOW TO CLEAN THE DOLE SOLENOID WATER FEEDERS IN THE MODULAR CONTROL BOX If water level does not shut off at the required 2/3 full in sight glass and Microswitch B is set correctly, this indicates that sediment has become lodged on seat of solenoid water feeder keeping valve in open position. To Service: A. Flush down boiler B. Shut off water supply C. Shut off main power D. Remove front cover from modular control box E. Break tubing connections at bottom of solenoid valves (A)
Microswitch A prevents the source of power from coming on until there is an adequate supply of water in the boiler. Microswitch B shuts off the water supply when the water level is approximately 2/3 from the top of the sight glass. WATER LEVEL When the boiler is full, water level should be 2/3 from the top of sight gauge and the water feed should shut off. If this is not correct, remove cover to water level control and adjust Microswitch B. CAUTION - Before removing cover disconnect
110V power supply. To adjust, loosen lock nut and turn screw clockwise to raise level and counter clockwise to lower level. If no water is visible in gauge glass and power comes on when water switch is reset, this indicates that: 1. The float of the water level control has become detached during transit. Shut off power, open hand hole door and re-install float ball. 2. Or that microswitch A is out of adjustment and must be re-adjusted. To adjust remove cover to water level control and loosen lock nut and turn adjusting screw in a clockwise direction. Continue this adjustment so that fuel does not come on until the sight glass :., 2/3 filled with water. CAUTION: Before removing cover disconnect 110V power supply.
F.
Remove (4) four screws inside control box to remove
G.
bottom of control box (B). It is not necessary to remove the complete box. Disconnect w ires (1), (2), and (3) from solenoid coils
(wires are marked). H. To remove coil remove right rear screw (C) from solenoid valve. I
To remove valve to clean the seat or to replace, remove remaining (3) three screw (D). J. Reassemble or replace valve by reversing steps j-a. When replacing coil be sure that quick disconnects face front ofr'modular control box. Also arrow on valve should face front of control box.
5009
ADJUSTING WATTS 3/4" REDUCING VALVE 1. Release the adjusting screw lock nut and loosen the adjusting screw enough to release all tension on adjusting spring (1). 2. Turn steam on slowly. Then turn adjusting screw clockwise just enough to allow the valve to open slightly. Allow cooker to operate in this manor several minutes. 3. Turn adjusting screw down slowly, at intervals, until reduced pressure reaches the desired Point. (5 P.S.I.) 4. Tighten adjusting screw lock nut. 5. If chattering noise should occur turn adjusting screw located in bottom half of valve body, clockwise or counter-clockwise, uniti chattering stops.
Replacement Parts For Type W ¾ Pressure Reducing Valve ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12
PART NO. 10-1083 10-1082 10-1075 10-1076 10-1077 10-1078 10-1079 10-1080 10-1081 10-1033 10-1034 10-0893
DESCRIPTION Adjusting Spring Diaphragm Diaphragm Gasket Diaphragm Button & Stem Assembly Strainer Bottom Plug Gasket Bottom Spring Seat Disc Assembly 3/4" Complete Valve-Painted 3/4" Complete Valve-Chrome Bottom Plug Valve Stem Guide
WATTS PRESSURE REDUCING VALVES - 3/4" To provide adequate steam pressure regulation, your unit may be equipped with a Watts steam pressure reducing valve. The 3/4" Watts pressure reducing valve is designed to operate from a 7 to 50 P.S.I, source of steam pressure and reduce this to 5 P.S.I; for delivery to your cooker. Installation must be made from your source of steam supply, through the pressure reducing valve, and into the manifold input part of the steam cooker. WARNING: Before final connection is made, blow down your steam line to remove all dirt, scale, packing and compound which may have accumulated during the installation of piping to the cooker. OPERATION OF WATTS 3/4" REDUCING VALVE
INSPECTION - MAINTENANCE ,
Reports of unsatisfactory regulation of the pressure reducing valve is usually due to dirt, pipe compound, etc., blocking the internal strainer, or gumming up the seat and disc assembly. To clean the strainer, seat, and disc assembly remove the bottom plug (6) and remove strainer screen (5), bottom spring (7) and disc assy. (9) Clean the lower part of the valve. This can be accomplished without removing the valve from the line or unbolting the cover. If cleaning the strainer and disc assy. does not correct fault, the disc assy. and seat should be replaced. Also the top cover should be removed and the diaphragm button stem assembly should be removed and cleaned.
REPAIRS The following item should be cleaned or replaced should the value fail to operate properly. 1. Both the disc assembly (9) and strainer (5) are removed by removing the bottom plug (11) and bottom spring (7). Upon cleaning or replacing these items, be sure that the disc assembly (9) is seated properly on the stem assembly (4) otherwise the stem assembly will be bent restricting its movement and the regulation of steam through the valve. 2. Should there be a restriction in the diaphragm button and stem assembly (4) it will cause a drop in steam flow or large fluctuations in steam pressure. It is then necessary to replace diaphragm button and stem assembly (4), valve stem guide (12) and diaphragm gasket (3) as well as those items in step 1. Upon completion of the above and removal of any loose scale, which may be found in the valve, the valve should be reassembled; and upon installation, function properly.
Steam enters the valve at the inlet port and passes upward through the seat (8) into the discharge side of the valve. As pressure in the discharge side increases, it forces the diaphragm (2) upward, overcoming the tension of the adjusting spring (1) and closing valve. As the pressure drops, the adjusting spring forces the diaphragm down, reopening the valve. Where demand and initial pressures are fairly constant, the valve opens to the proper position and maintains the desired reduced pressure.
5010
24 Inch Cabinet
ITEM NO. 1 Kit 2 Kit 3 4 5 Kit 6 7
PART NO. 90-2657 90-3013 90-2661 90-9039 10-0631 90-8974 90-2993 90-9098 90-3154 90-2663 10-0493
DESCRIPTION Rear Panel St. Steel Rear Panel St. Steel Kit Side Panels R & L St. Steel Side Panels R & L St. Steel Kit Leg Ass'y. 24" x 33" Modular Frame Door Ass'y. L Hand St. Steel Door Ass'y. L Hand St. Steel Kit Door Ass'y. R Hand St. Steel Panel MTG Bracket Feature Strip
ITEM NO. 8 9 10 11 12 13 14
PART NO. 90-3210 10-5561 10-1869 10-0454 10-0453 10-2365 10-2511 10-2307
DESCRIPTION Bracket Magnetic Catch Magnetic Catch No. 10-32 x 1/2" Flat Head Screw Cabinet Hinge Right Bottom Cabinet Hinge Left Bottom Lock Nut Washer Hex Nut
5011 A
36 Inch Cabinet
ITEM NO.
PART NO.
DESCRIPTION
1 2
90-2663 10-2405
Panel MTG Bracket Washer
3
10-2307
4
90-2656
PART NO.
DESCRIPTION
11 12 Kit
90-9062 90-9084
Door Ass'y. L Hand St. Steel Door Ass'y. L Hand St. Steel Kit
Hex Nut 5/16-18
12
90-9061
Door Ass'y. R Hand St. Steel
Rear Panel St. Steel
Kit
91-2140
Door Ass'y. R Hand St. Steel Kit
90-3078
Rear Panel St. Steel Kit
13
10-5561
Magnetic Latch
5
10-0631
Leg
14
90-3210
Bracket Magnetic Latch
6
90-2661
Side Panels R & L St. Steel
15
10-0494
Feature Strip
90-9039
Side Panels R & L St. Steel Kit
16
10-0453
Cabinet Hinge Left Bottom
7
10-2365
Self-Locking Nut
17
10-0636
Rear Legs w/Flange (Only on
8
90-9023
Ass'y 36" x 33" Modular Frame
9
10-0454
Cabinet Hinge R. Bottom
18
10-2511
Lockwasher 5/16
10
10-1869
No.10-32 x 1/2" Flat Head
19
10-2147
Hex Bolt 5/16-18
Kit
Kit
ITEM NO.
Tilting Skillet)
Machine Screw
5012B
NOTES: 1. 16 GA 125CG.E. VULKENE INSULATED MOTOR & APPLIANCE LEAD WIRE 2. ALTERNATE WIRESFF-2 (SEWF-20) 600V, 150C- COPPER CONDUCTOR INSULATED WITH 1/32 WALL OF SILICONE COATED WITH FIBERGLASS. 3. UNIT MUST BE GROUND. 4. WIRESNUMBERED 1 2 7 10 13 & 22 TO BE WHITE WIRE – ALL OTHERS TO BE BLACK 5. THIS WIRING DIAGRAM APPLIES ONLY WHEN BOILER IS EQUIPPED WITH NORMALLY OPEN DRAIN VALVE
For Normally Open ASCO Valve
COMPONENTS MARKED WITH ASERISKS ARE MOUNTED ON CONTROL BOX COVER
C10-6077D
NOTES: 1. 16 GA 125CG.E. VULKENE INSULATED MOTOR & APPLIANCE LEAD WIRE 2. ALTERNATE WIRESFF-2 (SEWF-20) 600V, 150C- COPPER CONDUCTOR INSULATED WITH 1/32 WALL OF SILICONE COATED WITH FIBERGLASS. 3. UNIT MUST BE GROUND. 4. WIRESNUMBERED 1 2 7 10 13 & 22 TO BE WHITE WIRE – ALL OTHERS TO BE BLACK
For Normally Open ASCO Valve
C10-6077D *COMPONENTS MARKED WITH ASTERISKS ARE MOUNTING ON CONTROL BOX COVER
ELECTRIC DIAGRAM OF CONTROL BOX FOR MANUAL BOILERS WITH MANUAL RESET
NOTES: 1. 16 GA 125 C G E VULKENE INSULATED MOTOR APPLIANCE LEAD WIRE. 2. ALTERNATE WIRE – INSULATED WITH 1/32 WALL OF SILICAN COATED WITH FIRBERGLASS 3. UNIT MUST BE GROUNDED 4. WIRES NUMBERED 1 7 10 & 22 TO BE WHITE WIE- ALL OTHERS TO BE BLACK
MODULAR
C10-6081A
•
COMPONENTS MARKED WITH ASTERISKS ARE MOUNTED ON CONTROL BOX COVER 5014
TROUBLES Pilot will not ignite.
Pilot lights but does not hold.
Water does not enter boiler.
1. 2.
POSSIBLE CAUSE Gas not reaching unit. Main "gas cock knob" not in pilot position.
1. 2.
REMEDY Check to make sure gas is turned on. Depress and turn "main gas cock" to pilot position-frefer to lighting instructions). Relight-hold valve depressed for longer period of time (one minute).
3.
Main "gas cock knob" not depressed long enough to pre-heat the pilot thermocouple.
3.
4.
Air pocket or dirt in gas line.
4.
Purge or blow out gas line.
1.
Main gas cock knob not held in long enough to eliminate all air in gas line.
1.
Hold in longer - refer to lighting instructions.
2. 3.
Defective wiring or poor connection. Thermocouple not generating sufficient millivolts to operate.
2. 3.
4. 5.
4. 5.
6.
Power unit of gas valve defective. Defective switching across either the water level control or pressure switches. Defective gas valve.
Check - replace or tighten. With the main gas cock knob in the "pilot" postion and manually depressed. A reading of between 10 and 20 millivolts should be read across terminals PP-PP. Replace if defective. Replace gas valve. Make continuity check - replace units that are defective. Replace gas valve.
1. 2.
Water main shut off. Power not reaching solenoid water feeder.
1. 2.
3.
Defective water micro-switch in water level control box or loose connection. Water level control micro-switch out of adjustment.
3.
Dirt or lime accumulation on seat of right solenoid valve in control box. Defective solenoid coil on right valve in control box. Defective water switch (toggle switch on
5.
Clean valve seat and line strainer.
6.
Check coil for continuity - replace if defective. Check continuity. If defective replace.
4.
5. 6. 7.
6.
4.
7.
Turn on. Check main fuse and if 115V. is present at water feeder. Check continuity or loose connection replace left switch if defective. Follow instructions for re-adjusting left micro-switch. If readjusting or cleaning does not remedy-replace.
control box). Boiler overfills with water.
Water enters boiler very slowly.
1.
Water level control out of adjustment.
1.
2.
Solenoid valve fails to close.
2.
Follow instructions for readjusting. If readjusting does not remedy replace microswitches. Clean or replace entire unit. Clean seat and strainer of valve.
1.
Dirty strainer screen on right solenoid valve. Dirt or lime accumulation on seat of
1.
Clean or replace strainer screen.
2.
Clean valve seat.
2.
right valve. Indicator light, on control box, does not light when water switch is manually reset.
1. 2.
Indicator light defective. Time delay relay loose or defective.
1. 2.
Replace. Check for good connections. If all rightreplace.
Main Burners will not ignite.
1. 2.
Fuel switch in off position. No water in boiler.
1. 2.
Turn to on position. Check to be sure water switch is on. Check to be sure main water supply is on and 11'' supply to unit is on.
3.
Water level control out of adjustment
3.
Adjust, clean or replace.
or sticking.
5029
TROUBLES
POSSIBLE CAUSE 4. Main gas cock or supply line not open. 5. Pressure switch set too low.
4. 5.
REMEDY Open. Reset-if continuity check shows to
6. No voltage to gas valve.
6.
Check main fuse and wiring.
be defective - replace. 7. Gas valve defective.
7.
Replace.
Boiler fails to build up any pressure when water level is proper and fuel
1. Check to see that main gas is turned on. 2. Check to see that pilot is lit.
1. 2.
Turn on. Light pilot.
switch is turned on.
3. Check to see that gas valve is in burners
3.
Turn to burners on.
4.
Check for voltage thru right side of
on position. 4. Current flow is broken at water level control (ascertain with continuity check). 5. Current flow is broken at pressure control
microswitch, replace if defective. 5.
or high limit control switches due to defect
Re-adjust to proper setting - refer to instruction for re-adjustment, replace
(ascertain with continuity check).
if defective.
Water level in gauge glass fluctuates up and down.
1. Top shut off on water gauge glass is closed.
1.
Open.
Boiler fails to reach full operating pressure of 5 Ibs. of 15 Ibs.
1. Pressure gauge reads inaccurately. 2. Pressure control and high limit control
1. 2.
Replace. Follow instruction for readjusting.
3. Safety valve not seating properly.
3.
Clean or replace.
4. Water level too high.
4.
Adjust water level control - check
switches are out of adjustment.
water feed valve for sticking - clean or replace. 5. Steam trap on units receiving steam from
5.
boiler not closing sufficiently after venting. 6. Air vent and vacuum breaker not venting
Replace element in steam trap of unit being fed steam from boiler.
6.
Replace.
7.
See instructions on gas adjustments.
1.
Shut down boiler and relieve all pressure. Steam gauge indicator
properly. 7. Insufficient flames on burners or im proper gas supply. Boiler fails to cut off after reaching operating pressure.
1. Defective steam gauge reading.
should return to zero. If defective replace. 2. Pressure switch set too high or defective.
2.
Adjust or replace if defective.
3. Gas valve fails to cut off gas supply when
3.
Replace gas valve.
1. Pressure set too high . 2. Pressure gauge reads incorrectly.
1. 2.
Readjust. Replace.
3. Lime or dirt on seat of valve.
3.
Clean.
4. Weak spring in valve.
4.
Replace.
1. High limit switch set to low or operating
1.
Follow instructions for readjusting,
demands of pressure switch have been met. Safety valve blows off prematurely.
Boiler builds up to pressure, shuts down, and fails to come back on.
pressure control switch set too high.
Boiler cuts out after 10-15 minutes of operation.
1. Defective time delay relay. 2. Poor solder connections on relay socket.
1. 2.
see page No. 6 • Replace if defective. Replace relay. Resolder connections on relay socket.
Air vent and vacuum breaker leaking.
1. Not closing.
1.
Replace.
5030
TROUBLES Cold water condenser does not
1.
POSSIBLE CAUSE Main water line shut off.
REMEDY 1. Turn on.
function.
2.
Thermostat out of adjustment or defective.
2. Readjust for proper operation or replace if defective.
3.
Loose connection
3. Tighten.
4.
Solenoid valve defective.
4. Check coil for continuity, if open
Pressure reducing valve cannot be
1.
Dirty screen and seat.
1. Clean.
adjusted.
2.
Disc assembly defective.
2. Replace.
3.
Diaphragm ruptured.
3. Replace.
1.
Dirty strainer screen.
1. Clean or replace.
Pressure reducing valve vibrates or hums.
1.
Adjustment of sensitivity adjuster.
1. Readjust.
Product in cooker does not cook
1.
Air vent and'vacuum breaker is closing too
1. Preheat cooking compartments and vent
replace.
Pressure reducing valve doesn't let sufficient steam into compartment.
properly on first cycle .
soon.
air into compartment.
5031
SETTING OF BOILER CONTROL PRESSURE SWITCHES
Gas Boilers used to generate steam for a Steam-It, Jet Steam Cooker, or Kettle which operate at 15-PSI should be set as follows: Switch A should be set at 10-PSI and Swich B at 20-PSI. Gas Boilers used to generate steam for a compartment type steam cooker which operates at 5-PSI should be set as follows: Switch A should be set at 5-PSI and Switch B at 10-PSI. Dial C is the differential dial and should always be set at 1-PSI on both Switch A and B.
COLD WATER CONDENSER ADJUSTMENT - AUTOMATIC BLOW DOWN ONLY The function of the cold water condenser is to keep the temperature in the drain line from exceeding J 50° F, solenoid valve D will open and run cold water through the drain until the temperature drops below 150°F,, this may be adjusted by adjusting dial F. Solenoid valve D is the valve that controls the water flow to the cold water condenser. It has a built in water strainer which should be removed and periodically cleaned. Solenoid valve E is the valve that controls the water flow to the boiler.
5032
