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WET-BASE CAST-IRON MODULAR BOILERS

STEAM / GAS

APPLICATION GUIDE

Guidelines for the design, purchase and installation of Slant/Fin gas-fired steam modular boiler systems.

Introduction .............................................................................1

Ratings and dimensions .........................................................2

Boiler room air supply.............................................................3

Venting gas fired system .....................................................4,5

Gas main sizing ...................................................................6,7

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 instal

ation must also conform to the additional requirements of

Slant/Fin Instruction book publication No. GG-100-40 latest

edition.

All electrical wiring is to be done in accordance with the

National Electrical Code ANSI/NFPA No. 7 latest edition and

all local electrical codes. The unit must be electrically ground-

ed if an external power source is used.

In Canada, the installation must be in accordance wi

th s

tan-

dards 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.

Many state and local codes require intermittent ignition

devices for gas boilers. Please specify if necessary.

There are many varieties of steam heating systems. Because

of the wide range of field conditions, the design of these sys-

tems is beyond the scope of this manual. However, when

designing a steam Caravan boiler plant, certain guidelines

should be followed that are common to all modular steam

heating application.

This entire manual should be read prior to installing the

Slant/Fin Caravan steam system.

Safety – each module contains a dual combination gas valve,

ASME 15 lb Relief valve and pressure gauge.

INTRODUCTION OF FRESH WATER

Introduction of excessive amounts of fresh water into a sys-

tem can cause scaling and leave deposits in the boiler and

the surrounding water pipes. This will lead to inefficient boiler

operation and breakdown. Fresh water will enter the system

as a result of leaks such as may occur in underground piping.

Process applications that use fresh water require the use of

heat exch

angers. A

ny process application that results in intro-

duction 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 may be necessary to use a feed water treat-

ment to control the corrosive makeup of the fill water. Check

with the local

uthority to determine if the feed water will need

a conditioning treatment before being supplied to the boiler.

Typical steam system layout...................................................8

Steam piping design ...............................................................9

Installation and piping......................................................10,11

Boiler feed pump sizing ...................................................12,13

Wiring at module .............................................................14-16

CONTENTS

INTRODUCTION

Publication No. CG-10-SG

Printed in the U.S.A. 1112

1 2 3 4 5 6 ... 15 16

Shrnutí obsahu

Strany 1 - APPLICATION GUIDE

WET-BASE CAST-IRON MODULAR BOILERSSTEAM / GASAPPLICATION GUIDEGuidelines for the design, purchase and installation of Slant/Fin gas-fired steam modula

Strany 2

10INSTALLATION AND PIPING RECOMMENDATIONSWhen one or more steam boilers are replaced with a newCaravan modular boiler system, there are certain condit

Strany 3

11Figure 11: Steam modules, isolated banks (Note: For detail piping refer to pages 8 & 9)Figure 12: Steam modules, integrated banks (Note: For det

Strany 4

1212. Caravan modular boiler systems are often used as a replace-ment for old, large, inefficient boilers. Compared with older boilers, modern steam

Strany 5 - CONNECTOR LENGTH:

13OVERFLOWTANK WATERLEVEL AT /OR BELOWLEVELWATERBOILERMANIFOLDRETURNCHECKVALVEPUMPSTRAINERGSTM-13NORMAL TANKWATER LEVELSTRAINERPUMPVALVEBALANCINGSHUT-

Strany 6

14Sequence of operationWhen the building thermostat calls for heat, contacts (RC) of theR8285B control closes. This energizes the coils of R1 and R2re

Strany 7 - * per cubic foot

15MODULE 1BUILDINGTHERMOSTATL4079BMANUALHI LIMITR8385BTRANSFORMERR2L2L1L2L1MODULE 2 MODULE 3L1 L2 L1 L21256RGYWCRC/RELAY67M L.W.C.O.CONTROL42A LOW WAT

Strany 8 - BOILER WATER

120V24VBLK/YELWHT/YELBLACKWHITEREDVIOLETBLOCKED VENTSAFETY SWITCHMALE PLUGHARNESS)MALE PLUG ON ADAPTERRECEPTACLE B(CONNECTS TOWITH VENT DAMPERCABLEROL

Strany 9 - Maximum 5 modules per bank

2GXHT-600 Z 2 GXH-300 600 478 358 1492 14.78 16.8 1075 26 1⁄16” 59 1⁄8” 9” 7” 3” 11 17⁄32” 4’ 11 1⁄8”GXHT-900 Z 3 GXH-300 900 717 537 2238 21.42 25.2

Strany 10

3BOILER PLANT SIZINGOlder buildings may have a heat loss significantly less than thatof the original building. To size a replacement steam boiler pla

Strany 11

4VENTING A GAS-FIRED SYSTEMA boiler venting system provides an escape path for the productsof combustion. There are three major components for venting

Strany 12 - * Maximum 5 modules per bank

5CONNECTOR RISE:Connector rise is the length of the pipe connecting the top of thedraft hood to the system breeching above. The diameter of thispipe v

Strany 13 - F

6GAS PIPINGThis section contains sizing and construction recommendationsfor fuel supply piping to Caravan gas-fired modular boiler sys-tems. Gas-fire

Strany 14 - 5 MODULES

7Table 6: Characteristics of various fuel gasesNatural 1000 Btu 1.00Propane 2500 Btu 1.10Typeof GasHeating Valve †FlowCorrectionFactor1⁄4 .364 32 22 1

Strany 15 - M

8RELIEFOVER-FLOWVALVETAPPINGSKIMMERRETURN1-1/4" TAPPINGFOR CONDENSAT EGLASSBLOWDOWNSITERETURN AND MAKE UPFROM FEED PUMPDRAINAGEPIPE TO DRAINSYSTE

Strany 16 - Figure 16: Wiring at module

9STEAM SUPPLY AND RETURN PIPINGModular steam boilers must be piped in a way that provides near-ly equal steam pressure at all modules. Supply and retu

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