Slant/Fin VICTORY II VHS Series Application Manual

Brand: Slant/Fin

Model: VICTORY II VHS Series

Type: Application Manual

HOT WATER/GAS

MODULAR BOILERS

APPLICATION GUIDE

Printed in the U.S.A. 1008 Publication No. CJ-10-HWG

www.slantfin.com

Guidelines for the design, purchase and installation of Slant/Fin Jaguar Caravan gas-fired, hot water modular boiler systems.

CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Recommended Piping . . . . . . . . . . . . . . . . . . . . . .2

Optional factory supply and return headers . . . . . .7

SC- control bill of materials . . . . . . . . . . . . . . . . . .9

Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Field wiring at modules . . . . . . . . . . . . . . . . . . . . .12

SC-3 system wiring . . . . . . . . . . . . . . . . . . . . . . . .12

SC-9 space heating wiring . . . . . . . . . . . . . . . . . .14

SC-9 space and domestic hot water wiring . . . . .16

CODES AND STANDARDS

All Caravan installations must comply to local codes or, in the

absence of local codes, to the National Fuel Gas Code, ANSI,

Z223.1-latest edition.

In addition where required by the authority having jurisdiction, the

installation must conform to American Society of Mechanical

Engineers Safety Codes for controls and safety devices for

automatically fired boilers, No. CSD-1. The installation must also

conform to the additional requirements of Slant/Fin Instruction Book

publication no. J-40 latest edition.

All electrical wiring is to be done in accordance with the National

Electrical Code ANSI/NFPA No. 70-latest edition and all local electri-

cal codes. The unit must be electrically grounded if an external

power source is used.

In Canada, the installation must be in accordance with standards

CGA B149.1 and B149.2, installation codes for gas burning

appliances and equipment and/or local codes. All electrical

connections are to be made in accordance with Standard C.S.A.

C22.1 Canadian Electrical Code Part 1 and/or local codes.

INTRODUCTION OF FRESH WATER

Introduction of excessive amounts of fresh water into a system can

cause scaling and leavedeposits in the boiler and the surrounding

pipes. This will lead to inefficient boiler operation and breakdown.

Fresh water will enter the system as a result of hidden leaks such

as mayoccur in underground piping. Relief valves should be piped

to a location that shows visible signs of relief.

Process applications that use fresh water,require the use of heat

exchangers. Any process application that results in introduction of

fresh water into a boiler can cause scaling with deposits forming in

the boiler and surrounding piping. This will damage the boiler.

Introduction of fresh water from leaks will cause similar damage.

In some areas it maybe necessaryto use a feed water treatment to

control the corrosive makeup of the feed water. Check with the local

authority, to determine if the feed water will need a conditioning

treatment before being supplied to the boiler.

Jaguar Caravan Modular Boilers2

INTRODUCTION

This application manual is intended to provide the piping and control

method for applying multiple Jaguar J-390 boilers to a space heat-

ing and domestic hot water heating system. Use this manual, in

conjunction with the Jaguar J-390 Installation and Operating

Instructions, publication J-40.

The following sections of the Installation and Operating Instructions

must be adhered to:

1. Boiler location and foundation

2. Clearances to combustibles

3. Contamination prevention

4. Air supply and ventilation

5. Venting application and materials*

6. Water treatment

7. Condensate disposal

8. Operating instructions

9. Care and Maintenance

*Common venting of these appliances is not permitted. Vent pipes in

anon-direct venting system can be clustered together, at their termi-

nation point. Direct vent terminals cannot be clustered together or

stacked vertically. Direct vent terminals can be mounted side by side

horizontally,provided there is a 12" minimum distance between

them.

RECOMMENDED PIPING AND WATER FLOW

Good system design addresses flow rates through boilers. It is

possible to have too little flow and too much flow. Most boiler sys-

tem designs are based on a 20˚F to 30˚F temperature rise in the

boiler when it is firing at full input.

When the flow rate is too high through a module the water flow

tends to short circuit from the return tapping to the supply tapping

of a module. When flow rate is too high the boiler efficiency may

drop and there is excess electrical consumption by the circulator.

Primary/secondary piping is recommended for multiple Jaguar

boilers. This method ensures that each boiler will receive the

same inlet water temperature, and only the boilers that are firing

will have water flowing through them. Each boiler must have a

dedicated circulator piped on it’s supply. See figures 1a through 4

for the location of components and piping layout.

If a single low water cutoff is installed in the common header

water piping to protect all of the boilers, no isolation valves are

permitted on the individual boiler piping between the low water

cutoff and each boiler. See figures 1a and 2a.

If isolation valves are installed in the individual boiuler piping to

the common headers, a dedicated low water cutoff must be

installed on each boiler’s piping, as close to the boiler as possible

and beneath the isolation valves. See figures 1b and 2b.

SPACE HEATING

The primary loop must have its own system pump, and closely

spaced tees for the secondary loop interconnection. By keeping

the pressure drop very low, water that is flowing in the primary

loop will not flow into the secondary circuit until each boiler’s cir-

culator turns on.

DOMESTIC HOT WATER HEATING

Amotorized valvecan be installed within the supply water heater

to divert the water flow of one or more boilers to a heat exchang-

er during a domestic water need. See figures 2a and 2b. This can

provide instantaneous delivery or storage of the domestic hot

water. See figures 2a through 4 for method.

Jaguar Caravan Modular Boilers 3

Figure 1a. Jaguar multiple boiler space heating primary- secondary pumping system with low water cutoff in common header.

Jaguar Caravan Modular Boilers4

Figure 1b. Jaguar multiple boiler space heating – Primary-secondary pumping system with low water cutoffs on each individual boiler.

Jaguar Caravan Modular Boilers 5

Figure 2a. Jaguar multiple boiler space heating and domestic hot water primary-secondary pumping system with low water cutoff in common header.

Jaguar Caravan Modular Boilers6

Figure 2b. Jaguar multiple boiler space heating and domestic hot water.Primary-secondary pumping with low water cutoffs on each individual boiler.

Jaguar Caravan Modular Boilers 7

Header System Parts Quantity needed for number of boilers installed

Item PartNo. 2 3 4 5 6 7 8 9

1-1/2" Stub Header - 2 stub - 27" C-C (pkgd. separately) 43-0920 2 – 4 2 – 4 2 –

1-1/2" Stub Header - 3 stub - 27" C-C (pkgd. separately) 43-0921 – 2 – 2 4 2 4 6

Flex Joint 1-1/2" pipe 43-2023 2 4 4 6 8 8 10 12

Flex Joint - 3" pipe 43-1755 4 4 8 8 8 12 12 12

Cast End Cap - No tap 43-1753 2 2 2 2 2 2 2 2

Gaskets are EPDM with +275˚F maximum temperature rating.

Maximum pressure rating exceeds maximum boiler pressure rating

of 30 psi.

Flexjoint is designed to seal pipe connections.Normal hangers,

guides, anchors and other external piping restraints must be used to

restrain piping system from movement.

•Some governing agencies do not allow compression type

couplings. Consult your local code requirements.

•Building piping must be rigidly secured so it cannot movewhere

connected to headers.

Figure 5. Header assembly for multiple Jaguar boilers

OPTIONAL EQUIPMENT (See figure 5) Header and Control Systems Available:

*Header Notes:

Figure 3. Instantaneous tankless coil—

two temperature with recirculation

Figure 4. Storage tank from tankless coil with recirculation

Jaguar Caravan Modular Boilers8

Caravan Flex Joint Assembly Instructions

1. Slip the metal retainer on the system piping with the larger

diameter side facing the end of the pipe to be joined. The

3"flex joint has a single piece serrated metal retaining

ring. This retaining ring should be seated in the recess in

the inner diameter of the gasket with its mounting tabs

over-lapping slightly where the ring splits. The 1-1/2" flex

joint has a 2 piece serrated retaining ring that must be

installed in the inner recess of the gasket with its ends

butting.

Work the gasket with the serrated metal retaining ring onto the pipe. When installing the gasket be sure the retaining rings

seat properly around the pipe. On the 1-1/2" flex joint install the bottom half of the gasket first leaving the other half of the

retaining ring free at the top. Then stretch the top of the gasket with the ring over the top of the pipe. When installing the

gaskets if a lubricant is needed, use a soap and water solution only. DO NOT use any oil based lubricants.

2. The gasket must be fully seated in the metal retainer (press together with pliers if necessary). BE SURE THE GASKET IS

SEATED ON AN UNTHREADED SECTION OF PIPE AT LEAST 1" FROM THE END. Slip the flared end of the Slant/Fin

header tube over the pipe and seat against the gasket. Follow illustration a or b for cast end cap or piping.

a) b)

3. Open hinged metal clamp and slip over joint. Be sure that the flared end of the steel tubing, the retainer ring and the

gasket are enclosed within the clamp.

Jaguar Caravan Modular Boilers 9

GAS PIPING

This section contains sizing and construction recommendations

for fuel supply piping to Caravan gas-fired modular boiler sys-

tems. Gas-fired equipment must conform not only to codes of

local regulatory agencies, but also to additional specifications that

may be imposed by the utility or gas supplier. Therefore, the fol-

lowing information should be considered only as a guideline.

Figure 6 illustrates a typical gas supply line installation. It consists

of a main between the utility’s meter box and the boiler system, a

main shut-off valvesediment trap,gas header pipe and drip legs

on individual boilers.

Individual gas lines to individual boiler modules should be equal

to or greater than the boilers supplied gas connection diameter.

Size of gas main and header pipes depends on volume of gas

required and acceptable pressure drop between meter and mod-

ules gas regulator valves. Minimum pressure required at each

valve is 3 inches of water column for natural gas measured while

all boilers and other gas-fired equipment on the same meter are

firing. Final pressure of gas header must vary no more than +0.3

in. of water column.

GAS MAIN SIZING

To determine the correct pipe diameter for the gas main serving a

specific Caravan system, proceed as follows:

a. Follow the building plans, find total length of straight pipe

between supply from gas meter and boiler gas header.

b. Using data in Table 2, calculate equivalent linear length of

screw pipe fittings used in fabrications of main. Add this to

figure from step (a) to obtain equivalent total length.

c. Find Caravan gas consumption in cubic feet per hour from

Table 1 in hot water systems.

d. Multiply the system total hourly gas consumption byflow

correction value from local utility. If not available, use

1000 btu/ft.

e. Locate system’s total equivalent pipe length in right column

of Table 3.

f. Move vertically to the system’s corrected flow rate calculated

in step (c). If this value falls between two of those listed,

selected larger value.

g. From this point move horizontally to the left column and read

suggested pipe diameter for gas main.

Table 2. Equivalent linear length in feet of standard iron pipe fittings for natural gas

Number

of boilers Cubic feet

per hour

2 780

3 1170

4 1560

5 1950

6 2340

7 2730

8 3120

9 3510

Table 1. Gas consumption rate.

Pipe

SIze

Inches

Elbow Valve Return

Bend

Side

Outlet

Tee

Standard Medium

Sweep

Long

Sweep Gate Globe Angle

1/2

3/4

1-1/4

1-1/2

0.84

1.17

1.57

2.19

2.63

3.55

5.72

0.52

0.73

0.98

1.37

1.64

2.23

3.59

0.41

0.57

0.77

1.07

1.29

1.74

2.81

0.031

0.044

0.057

0.082

0.098

1.320

2.130

2.50

3.50

4.68

6.54

7.84

10.60

17.08

1.12

1.84

2.11

2.94

3.52

4.77

7.69

1.25

1.75

2.34

3.27

3.92

5.30

8.84

1.66

2.33

3.11

4.35

5.21

7.05

11.40

BILL OF MATERIALS FOR SC SERIES CONTROLLERS

Material List for SC-3

• SC-3 modular boiler control (part#435-084)

•1Outdoor sensor (part#339-070)

• 1 Universal sensor to be used as supply water sensor

(part#339-071)

• 1 plastic tie strap

Material List for SC-9

•1SC-9 modular boiler control (part#435-085)

• 1 Outdoor sensor (part#339-070)

•2Universal sensors (part# 339-071)

–1to be used as supply water sensor

–1can be used as return water sensor

• 2 plastic tie straps

Other Options include:

•Immersion well for supply water sensor: to be installed in

control header supplied with Caravan

• High limit (manual reset) and immersion well: to be installed in

control header supplied with Caravan

• Low water cut-off (manual reset): to be installed in modular

boiler headers above modules heat exchanger

• Domestic hot water control packages: components include

EMV valve; setpoint aquastat L6006A with immersion well.

This is to be used with external heat exchanger such as

Caravan BP series brazed plate heat exchangers.

Circulators, switches, wiring and other relays are provided by

contractors.

Jaguar Caravan Modular Boilers10

Figure 6. Typical gas supply installation for Jaguar boiler.

Nominal

Iron Pipe

Size Inches

Internal

Diameter

Inches

Equivalent Length of Pipe, Feet

10 20 30 40 50 60 70 80 90 100 125 150 175 200

1/2

3/4

1-1/4

1-1/2

.622

.844

1.049

1.380

1.610

2.067

2.469

3.068

4.026

132

278

520

1,050

1,600

3,050

4,800

8,500

17,500

190

350

730

1,100

2,100

3,300

5,900

12,000

152

285

590

890

1,650

2,700

4,700

9,700

130

245

500

760

1,450

2,300

4,100

8,300

115

215

440

670

1,270

2,000

3,600

7,400

105

195

400

610

1,150

1,850

3,250

6,800

180

370

560

1,050

1,700

3,000

6,200

170

350

530

990

1,600

2,800

5,800

160

320

490

930

1,500

2,600

5,400

150

305

460

870

1,400

2,500

5,100

130

275

410

780

1,250

2,200

4,500

120

250

380

710

1,130

2,000

4,100

110

225

350

650

1,050

1,850

3,800

100

210

320

610

980

1,700

3,500

Table 3. Gas main sizing guide

Maximum capacity of pipe in cubic feet gas per hour for gas pressure of 0.5 psig or less and a pressure drop

of 0.3 inch water column (based on a 0.60 specific gravity gas).

Jaguar Caravan Modular Boilers 11

The Boiler Staging Concept

The heart of the Caravan boiler plant is temperature-actuated con-

trol system that automatically stages only those boiler modules

needed to meet the heating demand in a given period, thereby con-

serving fuel.

In a staging control system, each stage ordinarily activates one boil-

er module. With appropriate wiring, multiple modules can be

grouped within a stage.

During a fluctuation in heating requirements, a large central boiler

cycles on and off to match heat output to building demand. A

staged modular boiler system, on the other hand, will energize only

as many modules as the system load requires. Only one stage

cycles at a time. The other stages remain off or operate continuous-

ly, thereby performing at peak efficiency. For example, in a 10 mod-

ule boiler system, with the heating load at 61% of capacity, six of the

modules operate continuously at peak efficiency. Fractional heating

requirements are supplied by the seventh “cycling” modules, while

the remaining three modules are “off”. This is in contrast to a single

large central boiler that simply cycles on and off, resulting in lower

efficiency.

Over-sizing is a major factor in poor system efficiency. Most of the

time a single central boiler is oversized. Historical data shows that

many single central boilers are considerably oversized even at the

outdoor temperature for which they were designed. Modular boiler

systems are not oversized bymore than a portion of one module,

regardless of the load.

The Caravan control system automatically compensates for season-

al temperature changes, It energizes more or fewer modules

depending on changes of outside temperature,system water tem-

perature, or both. Modules save energy by operating in long cycles

at full-rated output and maximum efficiency.

Control System Selection

Slant/Fin offers two controls to step fire a hot water Caravan system.

The SC-3 and Sc-9 controls fulfill a wide range of applications. They

control the boiler system and are not intended to be the sole build-

ing temperature control. They do not replace zoning the system or

the thermostats that control these zones.

SC-3 Controls

The SC-3 control allows up to 3 stages in a Caravan system.

Generally each stage controls 1 module. However, it is possible to

have more than 1 module activated with each stage.

See figures 7a and 7b.

Standardprogrammable features include: system activation or

de-activation based on outdoor temperature; minimum target supply

water temperature; adjustable design target supply water tempera-

ture; adjustable delay between stages adjustable outdoor tempera-

ture and indoor design temperatures.

The view menu on the control includes error messages, actual out-

door air temperature, actual supply water temperature target supply

water temperature and running time for each stage.

The SC-3 control can be programmed as follows:

1. Outdoor reset: The supply water temperature is

automatically adjusted up or down based on outdoor

temperature. the control automatically controls the

number of modules required to maintain required supply

water temperature.

2. Setpoint temperature: The control can be programmed to

maintain a set supply water temperature. The control

automatically controls the number of modules activated to

maintain the setpoint temperature.

SC-9 Controls

The SC-9 control allows up to 9 stages of operation for space heating,

domestic water or combination, in a Caravan system. Generally each

stage controls 1 module. However, it is possible to have more than one

module activated with each stage, See figures 8a through 10b.

Standard programmable features include: system activation or

de-activation based on outdoor temperature; minimum target supply

water temperature; adjustable design target supply water tempera-

ture; adjustable delay between stages; adjustable outdoor and

indoor design temperatures; delay to allow combustion air damper

to open; ability to provide equal run time rotation of boiler modules;

fixed lead of a module when Caravan system activates; first on/last

off or first on/first off for modules; control of primary circulator and

periodic exercising of primary circulator when system is inactive.

The view menu on the control includes error messages, actual out-

door air temperature, actual supply water temperature, target water

temperature, running time for each stage and the difference

between supply water and return water temperatures.

The Sc-9 control can be programmed as follows:

1. Outdoor reset: The supply water temperature is

automatically increased as outdoor temperature decreases

and decreased as outdoor temperature increases.The

control activates only the number of stages required to

maintain the required supply water temperature.

2. Setpoint temperature: The control maintains a set supply

water temperature. The control activates only the number of

stages required to maintain the setpoint temperature.

Setpoint temperature maybe used for Caravan system

that is dedicated for use as volume water heating.

3. Domestic hot water: The domestic hot water controls

override the SC-9 control for only those modules used to

heat the domestic hot water. The modules for domestic hot

water are isolated from space heating system until demand

for domestic hot water is satisfied. The modules not used for

domestic hot water heating remain under control of

SC-9 control.

Slant/Fin offers domestic hot water control packages and

external tankless heaters as options for use with the SC-9

control.

Controls Interaction

Each multiple boiler’s control must be programmed to properly

interact with the Caravan control, and all the parameters must be

consistent. There are 4 methods that can be utilized, based on

the desired function:

A. Caravan control using a thermostat/boiler control

programmed for fixed water setpoint temperature. Best

method for systems where domestic hot water is to be

generated. Each boiler’s modulation will be minimal.

B. Caravan control using a thermostat/boiler control utilizes an

outdoor sensor, provides more frequent boiler modulation.

Not recommended for domestic hot water generation.

C. Caravan control using an outdoor sensor/boiler control

programmed for fixed water setpoint temperature. Provides

some degree of boiler modulation, where domestic hot water

generation is needed.

D.Caravan control using an outdoor sensor/boiler control also

utilizes an outdoor sensor. Best methods for increasing boiler

modulation, providing the boiler’s control parameters are in

sync with Caravan. Not recommended for domestic hot water

generation.

Jaguar Caravan Modular Boilers12

Figure 7a. SC-3 space heating wiring diagram for Jaguar boilers with low water cutoffs in common header.

Jaguar Caravan Modular Boilers 13

Figure 7b. SC-3 space heating wiring diagram for Jaguar boilers with low water cutoffs on each individual boiler.

Jaguar Caravan Modular Boilers14

Figure 8a. SC-9 space heating wiring diagram for Jaguar boilers with low water cutoff in common header.

Jaguar Caravan Modular Boilers 15

Figure 8b. SC-9 space heating wiring diagram for Jaguar boilers with low water cutoffs on each individual boiler.

Jaguar Caravan Modular Boilers16

Figure 9a. SC-9 space heating and domestic hot water wiring diagram for Jaguar boilers with low water cutoff in common header - using plate heat exchanger

Jaguar Caravan Modular Boilers 17

Figure 9b. SC-9 space heating and domestic hot water wiring diagram for Jaguar boilers with low water cutoffs on each individual boiler – using plate heat exchanger.

Jaguar Caravan Modular Boilers18

Figure 10a. SC-9 space heating and domestic hot water wiring diagram for Jaguar boilers with low water cutoff in common header - using indirect water heater

Jaguar Caravan Modular Boilers 19

Figure 10b. SC-9 space heating and domestic hot water wiring diagram for Jaguar boilers with low water cutoffs on each individual boiler – using indirect water heater.