Slant/Fin VICTORY II VHS Series User guide

WET-BASE CAST-IRON MODULAR BOILERS
HOT WATER/OIL
APPLICATION GUIDE
INCLUDING
DUAL FUEL
Guidelines for the design, purchase and installation of lant/Fin oil-fired and dual fuel hot water modular boiler systems.
Introduction .............................................................................1
Boiler room design..................................................................5
Boiler room air supply re uirements.......................................5
Venting an oil-fired system ..................................................7,8
Fuel oil storage facilities .........................................................9
Fuel oil delivery systems for single fuel burners ...............9-11
Fuel oil delivery systems for dual fuel burners................11-14
Controls ...........................................................................15,16
CODE AND TANDARD
Oil-fired Caravan installations must comply to local codes or,
in the absence of local codes, to the ANSI/NFPA 31,
Installation of Oil Burning E uipment, latest edition.
In addition, where re uired 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 re uirements
of Slant/Fin Instruction Book publication no. L-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 electrical 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 oil
burning appliances and e uipment 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.
This Caravan application manual is intended to simplify the
selection and application of Slant/Fin modular systems for a
variety of space heating and domestic hot water re uirements.
Where any additional information is re uired, contract your
local wholesaler, Slant/Fin sales representative, or the
Slant/Fin factory.
A. Design flexibility - Caravan modular boiler systems are
available in virtually any size capacity simply by adding
modules.
B. Boiler room design, size and flexibility - since Caravan
modules have the burner and controls mounted to the
front, they can be installed with minimum clearances as per
codes, thus saving a significant amount of floor space.
C. Faster, easier installation - modules are completely
factory assembled, including individual jackets to save on-
site labor. Optional easy to install supply and return
headers with flexible uick connect fittings are available for
hot water systems.
D. afety - each module contains an individual high limit
control and a flame safeguard control. ASME relief valve is
provided separately for mounting directly on boiler.
E. Fast domestic hot water recovery - Caravan offers an
external heat exchanger of the positive circulating type.
INTRODUCTION OF FRE H WATER
Introduction of excessive amounts of fresh water into a
system can cause scaling and leave deposits 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 may occur in underground
piping. Relief valves should be piped to a location that shows
visible signs of relief.
Process applications that use fresh water, re uire 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. Use of fresh water will void warranty.
In some areas it may be necessary to 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.
Control Wiring Diagrams*:
SCG400, space heating only ......................................17,18
SCG400, space heating and domestic hot water .......19,20
SCG1200, space heating only ....................................21,22
SCG1200, space heating and domestic hot water .....23,24
SCG2000, space heating only ....................................25,26
SCG2000, Space heating and domestic hot water.....27,28
Field Wiring at Modules ........................................................29
Reset Ratio and Temperature Set Points .............................30
*All wiring diagrams are based on continuous circulation.
CONTENT
INTRODUCTION
Publication No. CG-10-HWO
Printed in the U.S.A. 1200
®

2
Table 1. Oil Caravan ratings hot water models — LDWO Series
(75 psi ma imum working pressure)
LDWO-600-2-5 2 4.30 602 500 2900 435 14.9 31.0 1570 2"
LDWO-750-2-6 2 5.20 728 596 3453 518 17.8 35.6 1790 2"
LDWO-850-2-7 2 6.00 840 684 3967 595 20.4 45.2 2000 3"
LDWO-900-3-5 3 6.40 896 750 4347 652 22.4 46.5 2355 3"
LDWO-1100-3-6 3 7.80 1092 894 5180 777 26.7 53.4 2685 3"
LDWO-1300-3-7 3 9.00 1260 1026 5947 892 30.6 67.8 3000 3"
LDWO-1700-4-7 4 12.00 1680 1368 7933 1190 40.9 90.4 4000 3"
LDWO-2100-5-7 5 15.00 2100 1710 9913 1487 51.1 113.0 5000 3"
LDWO-2500-6-7 6 18.00 2520 2052 11893 1784 61.3 135.6 6000 3"
LDWO-2900-7-7 7 21.00 2940 2394 13880 2082 71.5 158.2 7000 4"
LDWO-3400-8-7 8 24.00 3360 2736 15860 2379 81.7 180.8 8000 4"
Model No.
No. of
Htg.
Mod.
Firing
Rate
#2 Oil
GPH* Input
Ratings (MBH)
Gross
Output
‡ EDR
Water
( q. Ft.)
I=B=R
Net
Ratings
(MBH)†
Boiler
Horse-
power
Water
Content
(gal.)
hip
Wt.
Recom-
mended
Header
ize§
LDWO-600-2-5 215⁄887⁄32 834
3⁄84'4"
LDWO-750-2-6 25 929⁄32 837
3⁄44'4"
LDWO-850-2-7 283⁄81119⁄32 941
1⁄84'4"
LDWO-900-3-5 215⁄887⁄32 834
3⁄86'7"
LDWO-1100-3-6 25 929⁄32 837
3⁄46'7"
LDWO-1300-3-7 283⁄81119⁄32 941
1⁄86'7"
LDWO-1700-4-7 283⁄81119⁄32 941
1⁄88'10"
LDWO-2100-5-7 283⁄81119⁄32 941
1⁄811'1"
LDWO-2500-6-7 283⁄81119⁄32 941
1⁄813'4"
LDWO-2900-7-7 283⁄81119⁄32 941
1⁄815'7"
LDWO-3400-8-7 283⁄81119⁄32 941
1⁄817'10"
Model No. ‡ A B CD † L *
* 27" spacing between modules.
† Add 151⁄4" for dual fuel models.
‡ Dual fuel prefix is LWDF.
Note: Standard boiler unit prefix is LDWO.
Figure 1: Oil Caravan dimensions and typical piping/hot water models
* Light oil, 140,000 Btuh per
gallon.
† Net ratings are based on a
piping and pick-up
allowance of 1.15.
Slant/Fin should be
consulted before selecting
a boiler for installation
having unusual piping and
pick-up re uirements.
‡ Based on 150 Btuh per
s uare foot E.D.R. at
170°F average water
temperature.
§ Modules in excess of 8
are piped in parallel to first
eight.
For larger sizes, use
multiples of the above.

3
Minimum flow rate formula:
Minimum flow rate through modules =
Gross output (MBH)
20,000
Note: A water flow proving device
is recommended on all
Caravan systems.
Figure 2:
Recommended boiler piping for
variable volume zone circulation
Figure 3: Supply and return piping locations for space heat with domestic hot water
Figure 4: Instantaneous tankless coil—
two temperature with recirculation
Figure 5: Storage tank from tankless coil with recirculation
locations for space heat with domestic hot water
UGGE TED DOME TIC HOT WATER PIPING

4
EQUIPMENT INCLUDED
LDWO ERIE — Hot Water Models
Pre-assembled heat exchanger with built-in air separator.
Insulated baked enameled jacket.
Flue collector.
Draft regulator.
Flame retention oil burner with nozzle and CAD cell.
Primary burner control.
Temperature limit.
Flue brush.
Module temperature and pressure gauge.
System pressure and temperature gauge (unmounted-1 per system)
Pressure relief valve (unmounted-1 per module)
Control header (unmounted-1 per system, up to 8 modules)
OPTIONAL EQUIPMENT
Headers.
Control system.
Figure 6: Oil Caravan—optional header assembly for all models LDWO and LWDF hot water Caravan systems.
*Building piping must be rigidly secured so it cannot
move where connected to headers.
NOTE:
Shown reverse return (Preferred). For direct return,
header assembly piping connections may be made at
the same end of the boiler bank, not as shown.
Some governing agencies do not allow compression
type couplings. Consult your local code re uirements.

5
BOILER ROOM DESIGN
Caravan modular boiler systems allow better utilization of floor
space and permit future expansion with minimum cost.
Caravan modules are hand truckable, fit through doorways
and often may be installed around an existing inoperative
boiler. They can be grouped in heating module batteries of
single, multiple or angular rows. Oil-fired boiler systems
consisting of 9 or more modules should be piped in parallel in
two or more batteries. Illustrated below are typical boiler room
layouts and dimensional data on the size re uirements of oil-
fired hot water boilers.
BOILER ROOM AIR SUPPLY
To ensure safe, efficient operation, the modular boiler system
must be supplied with sufficient air to support complete
combustion, replacing air entering draft dampers or draft
hoods and ventilating the boiler room or areas.
For additional information, not listed below, see ANSI, Z223.1,
section 5.3.3.
INSTALLATION IN ENCLOSED BOILER ROOM REQUIRES
TWO UNOBSTRUCTED OPENINGS FOR PASSAGE OF
AIR INTO THE BOILER ROOM:
1. Air drawn horizontally from outdoors DIRECTLY
through an outside wall; one louvered opening near the
floor (below burner inlet) and one louvered opening near
the ceiling (above the highest draft regulator), each
opening with a minimum FREE air passage area of 1
square inch per 4000 BTUH of total system input.
2. Air drawn horizontally from outdoors through
HORIZONTAL DUCT ; one opening near the floor
(below burner inlet) and one opening near the ceiling
(above the highest draft regulator), each opening with a
minimum FREE air passage area of 1 square inch per
2000 BTUH of total system input.
3. Air drawn VERTICALLY from outdoors; one opening at
the floor and one opening at the ceiling, each opening
with a minimum FREE air passage area of 1 square
inch per 4000 BTUH of total system input.
4. Air drawn from inside the building; one opening near
the floor (below burner inlet) and one opening near the
ceiling (above the highest draft regulator), each opening
with a minimum FREE air passage area of 1 square
inch per 1000 BTUH of total system input.
IF BOILERS ARE INSTALLED ADJACENT TO OTHER
FUEL BURNING EQUIPMENT, THE AREA OF FREE
OPENINGS MUST BE APPROPRIATELY INCREASED TO
ACCOMMODATE THE ADDITIONAL LOAD.
UNLESS PROPERLY CONTROLLED, AVOID THE USE OF
FORCED VENTILATION, SINCE IT CAN CREATE AN
UNDESIRABLE PRESSURE DIFFERENTIAL BETWEEN
BOILER ROOM AND AIR SOURCE.
Figure 7. Correct location of combustion-air supply ducts

6
Figure 8. Typical layouts oil-fired systems
* Caravan can be installed as close as 1" from the wall, local codes
permitting. However, 24" is recommended for service inspection
access.
∆See Figure 1 dimensions A and D.

7
VENTING AN OIL-FIRED SYSTEM
A boiler venting system provides an escape path for the
products of combustion. In a venting system for an oil-fired
Caravan, there are three major components: a riser with draft
regulator for each module, a breeching manifold, and a
chimney.
Sometimes the venting system for a boiler plant has to be
designed to compensate for inade uate chimney conditions.
A mechanical draft inducer, properly sized and installed, can
usually increase chimney capacity sufficiently to provide
proper venting. Where a draft inducer is called for, consult
local codes and the recommendations of the mechanical draft
inducer manufacturer. Normally, a draft proving device is
necessary to permit operation of the boilers only when
ade uate draft exists.
It is important to note that when considering a mechanical
draft inducer, the boiler room air supply re uirements must be
increased. Consult the draft inducer manufacturer for this
information.
Draft Regulator
The draft regulator compensates for excessive draft that can
be caused by varying weather conditions. The regulator
should be of the barometric-draft type. Once adjusted for a
particular venting system, this type regulator automatically
compensates for excessive draft to assure optimum operating
efficiency.
Breeching
Breeching is a term used to describe a manifold(s) that
connects individual boiler modules to a chimney. Breeching is
usually constructed of sheet metal having a smooth interior
surface with all joints made tight against leakage. The layout
of a particular boiler room may re uire that the modules be
arranged in "batteries" with rows either parallel or at right
angles. Minimum breeching sizes are given in Table 2.
To avoid creating turbulent air patterns in the breeching, it is
suggested that individual boiler vent pipes be connected to
the breeching as indicated in Figure 3.
The breeching manifold should extend into, but not beyond,
the chimney liner. Round breeching is preferable to
rectangular breeching.
Chimney
Caravan oil-fired modular boilers operate efficiently with
masonry or prefabricated chimneys. This latter type of
chimney construction is generally the least expensive.
Minimum chimney sizes and heights are given in Table 2. In
addition, the chimney should be high enough to minimize the
effects of turbulent winds and high pressure areas common
near roof-top obstructions. The National Board of Fire
Underwriters recommends that the chimney should extend 3
feet above the roof and be 2 feet higher than any obstruction
within 10 feet (figure 9). The use of a vent cap where
permitted by code gives additional protection against adverse
wind conditions and precipitation.
izing Breeching and Chimneys for Oil-Fired ystems
Breeching for oil-fired Caravan systems can be either constant
size or graduated. When constant size breeching is to be
installed, refer to Table 2. The use of graduated sections may
reduce breeching costs. Generally, it becomes economically
feasible to use this approach when boiler batteries exceed
four modules. In this case, each breeching section usually
serves two to four modules.
To size graduated breeching and chimneys for a Caravan oil-
fired modular boiler system, use Table 2 and 3 and the
following procedure:
LDWO-600-2-5 2 11" 84 4'8"
LDWO-750-2-6 2 12" 101 4'8"
LDWO-850-2-7 2 13" 115 4'8"
LDWO-900-3-5 3 13" 123 7'1"
LDWO-1100-3-6 3 14" 148 7'1"
LDWO-1300-3-7 3 15" 170 7'1"
LDWO-1700-4-7 4 16" 189 9'6"
LDWO-2100-5-7 5 18" 233 11'11"
LDWO-2500-6-7 6 19" 277 14'4"
LDWO-2900-7-7 7 21" 320 16'9"
LDWO-3400-8-7 8 22" 365 19'2"
Model No. * No. of
Modules
Breeching
Diameter
Minimum
Area
(sq.in.)
Breeching
Length
* Dual fuel prefix = LWDF.
Notes:
1. For breeching and chimney sizing over 8 modules, consult factory.
2. Breeching length should be as short as possible. Measurement from the
base of the vertical vent to the nearest connected appliance should be
limited to 10' or 50% of the total vent height, whichever is greater.
Table 2. Breeching dimensions for oil-fired systems —
LDWO Series
LDWO-600-2-5 2 11" 93⁄4" X 93⁄4" 20'
LDWO-750-2-6 2 12" 91⁄2" X 131⁄2" 20'
LDWO-850-2-7 2 13" 131⁄4" X 131⁄4" 20'
LDWO-900-3-5 3 13" 131⁄4" X 131⁄4" 20'
LDWO-1100-3-6 3 14" 131⁄4" X 131⁄4" 20'
LDWO-1300-3-7 3 15" 13" X 17" 20'
LDWO-1700-4-7 4 16" 13" X 17" 25'
LDWO-2100-5-7 5 18" 163⁄4" X 163⁄4" 25'
LDWO-2500-6-7 6 19" 161⁄2" X 201⁄2" 25'
LDWO-2900-7-7 7 21" 201⁄4" X 201⁄4" 25'
LDWO-3400-8-7 8 22" 201⁄4" X 201⁄4" 25'
Model No. * No. of
Modules
Dia.
Inches
Rectangular
L x W
Inches
Minimum
Height
Feet
Chimney Liner Inside Dim. †
* Dual fuel prefix = LWDF.
† Dimensions shown are from ASHRAE Guide E uipment Handbook. Also
select inside liner dimensions to give area as great or greater than shown in
this table. Chimney height is measured from the center line of the breeching
to the top of the chimney. Chimney dimensions are approximate. They are
based on use of type "B" double wall vents, connector and manifolds; no
manifold elbows or tees; and good vent construction practices.
Field conditions vary. It is doubtful that the chimney dimensions shown here
will be suitable for all applications. Consult the 1988 ASHRAE E uipment
Handbook and Chimney Manufacturers Sizing Handbook.
Table 3. Chimney requirements

8
a) Starting with modules in the section furthest from the
chimney, count the number of modules venting into that
section of breeching.
b) Find breeching necessary to vent these boilers.
c) Count the modules venting into the next section. To this
figure add the number of modules from the preceding
section, since their output also moves through the second
section.
d) Find the correct size breeching for the second section.
e) Repeat steps (c) and (d) for each section until breeching
for the entire battery has been sized.
f) If the system has more than one battery, repeat steps (a)
through (e) for each battery.
g) Where multiple breeching runs are re uired, a section of
common breeching is often used to join the multiple runs to
the chimney. To determine the size of this piece, add up
the total number of modules feeding it, and then refer to
Table 2 or chimney manufacturer's data.
h) Find the lengths of the various sections of breeching
needed for a particular job from Table 2.
i) To calculate the length of the battery-to-chimney breeching
section, use the method applicable to the type of breeching
as follows:
• Breeching for only one boiler battery. Measure the
distance between the chimney and nearest boiler. Add
this to the figure obtained in step (h).
• Breeching to multiple runs. Measure the distance
between the chimney and the first module of the boiler
battery that is in the same axis as the common
breeching. This is the length of common breeching,
measure the distance between side of the common
breeching and nearest boiler. Add this to the figure
obtained in step (h).
j) To determine the re uired chimney dimensions, total the
number of modules in the system and refer to Table 3.
Where building height exceeds the recommended
minimum chimney height, refer to chimney paragraph.
NOTE: These procedures DO NOT take into account all
possible field conditions. As with all generalized sizing
information, the final specifications should be tempered with
the engineer's practical experience, and the chimney
manufacturer's data, and ASHRAE Handbook.
Figure 9. Suggested venting system constructions

9
FUEL OIL TORAGE FACILITIE
Local codes usually govern the installation of fuel oil storage
facilities. However, for areas where no rules have been
established, the following information can provide assistance
to the system designer.
torage tank sizing
When calculating minimum fuel oil storage capacity, several
variables must be considered. These include: maximum fuel
consumption rate, storage space limitations, availability,
distance from source of supply, and method of delivery (truck
or railroad tank car). Large storage tanks, of course, cost
more than smaller ones but the cost is not proportional (e.g.,
a 10,000 gal. tank does not cost twice as much as a 5,000
gal. tank). And larger tank capacity allows oil purchases
usually at lower per gallon rates.
Generally, the storage tank should hold enough oil to sustain
continuous operation for 10 days (plus an additional 10%
margin to allow for suction stub clearance).
To determine the minimum storage re uirement, proceed as
follows:
a) Refer to Table 1 to find the maximum hourly oil
consumption (GPH) of the system being installed.
b) Multiply the maximum hourly consumption by the probable
maximum daily hours of operation to achieve maximum
daily consumption.
c) Multiply the maximum daily consumption by 10 (days) and
add 10% to obtain the MINIMUM storage capacity.
Requirements for fuel oil storage tanks.
Data in this section is based on the use of steel storage tanks.
Where no local codes apply, take the following data into
consideration.
a) Inside tanks are usually located in the lowest part of the
building. When supply and return lines are piped through
the top of the tank, spillage is minimized in the event of
leaks.
b) Unenclosed tanks should be at least 7 feet from any open
flames or fires.
c) Most fire codes prohibit unenclosed inside tanks exceeding
275 gallons each. Where multiple tanks are installed, the
total storage capacity should not exceed 550 gallons
unless vaulted.
d) If inside tanks are properly enclosed, the maximum storage
capacity can be increased to 5,000 gallons in non-fire-
resistant buildings, and to 15,000 gallons in fire-resistant
structures.
NOTE: An enclosure shall consist of walls constructed of
6" reinforced concrete or 8-inch thick masonry with the
space between tank and walls filled with sand. If floor
above has a load-bearing capacity of 150 lbs./s . inch or
greater and is constructed of fire-resistant material, 1 foot
of sand fill over the tank is sufficient. If not, a 5-inch
concrete slab, or e uivalent, must be employed. An
alternative method is to pour a 6-inch thick concrete
enclosure directly over the tank (no air spaces).
e) Underground tanks (Figure 10) are to be buried at least 2
feet below grade.
f) Tanks buried beneath buildings ALWAYS re uire 4-inch
reinforced concrete slab covers that extend 1 foot beyond
tank in all directions.
g) Fiberglass and/or double-walled tanks may be re uired.
Check your local codes.Underground metal tanks should
be painted with heavy asphaltum, rust-resistant paint or be
of double walled construction (check local codes). DO
NOT install tank in bed of cinders (cinders contain sulphur,
which becomes corrosive when wet).
NOTE: Before installing underground tanks, check local
surface water conditions. Where potential problems exist,
concrete anchors should be provided.
FUEL OIL PIPING
Figure 10. Typical e ample of properly installed
underground fuel tank
FUEL OIL DELIVERY Y TEM
FOR INGLE FUEL BURNER
General
Three methods for delivering oil to the individual burners are
described herein. These methods are chosen to provide
tempered, filtered and air-free oil to the individual burners.
Consistent oil uality will optimize burner operation over
longer periods.
There are variations to the methods described herein which, if
applied properly, will result in acceptable operation. These
methods are for reference only. Local codes vary. It is
important to check all codes for compliance.
Information herein has been compiled using data from
industry sources, including companies such as Mitco,
Webster, Suntec and Tuthill. For additional information on
these products, contact the representative in your area.
MFG data and safety codes vary with regard to maximum fuel
unit inlet pressure. Pay particular attention to the gravity oil
head. Be sure to add oil pressure reducing valves in the
event that codes or MFG data will be exceeded. 5 psi is
e uivalent to approximately 12 feet in height. (See "H"
dimension.)
torage tank above burners (Figure 11)
A simple one pipe connection from the supply tank to each
burner helps to eliminate air in the oil line and tempers the oil
in the pipe as it travels slowly to the burners.

10
This method maintains consistent fuel oil uality to the
individual burners and therefore decreases the fre uency of
maintenance and service. When a component breakdown
occurs in a burner or in the supply system, the trouble is
easily found and service is restored uickly.
torage tank below burners and gravity tank above
burners (Figure 12)
Oil is automatically and constantly maintained in the supply tank
at a level sufficient to meet all burner needs. As oil is used, the
pressure drop is sensed by a pre-set automatic pressure switch,
which signals the booster pump to restore proper level. There is
no practical limit on the height or distance that the motorized
pump can deliver oil to the supply tank.
The great advantage of the booster pump along with a gravity
tank is that it accomplishes its purpose in the most simple and
direct manner. This results in the most economical installation,
with the shortest possible runs of pipe and wire. It also
enables the installer to adapt with ease to almost any building
configuration. A simple one pipe connection to each burner
helps eliminate air in oil line with constant flow of fuel and
tempers the oil.
Simplicity of operation of the individual burner decreases the
chances that service will be needed. When a component
breakdown occurs in a burner or in the supply system, the
trouble is easily found and service is restored uickly.
Figure 11. Storage tank above burners
Figure 12. Storage tank below burners