Slant/Fin GAS Modular Boilers, HOT WATER Modular Boilers, Caravan GGHT-3500E Application Manual

®

HOT WATER/GAS Modular Boilers

APPLICATION GUIDE

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

CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Ratings and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . .3,4

Recommended Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Optional factory supply and return headers . . . . . . . . . . . . . .6

Boiler room design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Boiler room air supply requirements . . . . . . . . . . . . . . . . . . . .7

Typical layouts for gas-fired systems . . . . . . . . . . . . . . . . . . .8

Venting a gas-fired system . . . . . . . . . . . . . . . . . . . . . . . . .9,10

Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12

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. GG-100-40 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 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.

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13,14

Field wiring at modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

SC-3 system wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

SC-3 ladder wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

SC-9 space heating wiring . . . . . . . . . . . . . . . . . . . . . . . . . .18

SC-9 space heating ladder wiring . . . . . . . . . . . . . . . . . . . . .19

SC-9 space and domestic hot water wiring . . . . . . . . . . . . .20

SC-9 space and domestic hot water ladder wiring . . . . . . . .21

Caravan warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Request for Caravan rating plate . . . . . . . . . . . . . . . . . . .23,24

INTRODUCTION OF FRESH 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, 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 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.

y state and local codes require inter

Man
gas boilers

w

Ne

GGT and GGHT Caravan Modules - MEA 283-93-E Vol. II
Slant/Fin vent damper NYS approval No. 8859

Pennsylvania:

Caravan boilers are approved in Pennsylvania by PA Cert. 174-BT-S

Please specify if necessar

.

LOCAL

ork City:

Y

CODE

mittent ignition de

y.

O

APPR

ALS

V

vices f

or

Publication No. CG-10-HWG

inted in the U

Pr

www.slantfin.com

.A. 1104

.S

INTRODUCTION

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 requirements. It applies to
gas-fired, hot water applications only. Where intermittent pilot, vent
damper or an
wholesaler

y additional information is required, contact your local

, Slant/Fin sales representative, or the Slant/Fin factory.

Faster, easier installation

B.

- modules are completely f

actory
assembled, including individual jackets to save on-site labor.
Optional easy to install return and supply headers with flexible
quick connect fittings are available for hot water systems.

C. Safety - each module contains an individual high limit control

and a dual combination gas valve. ASME relief valve is provided

Due to design flexibility of a Caravan modular boiler system, BTU

separately for mounting directly on each module.

input capacities are unlimited.

A. Boiler room design, size and flexibility - since Caravan

. Fast domestic hot water recovery

D

heat exchanger of the positive circulating type.

avan offers an external

- Car

modules have the burner and controls mounted to the front, they
can be installed with minimum clearances as per codes, thus

ving a significant amount of floor space.

sa

Table 1: Gas Caravan ratings and dimension/hot water model—GGT Series (100 psi maximum working pressure)

Consists of

Module

Model

Number

Model No.

No.of

Htg.

Mod.

GGT-400E 2 GG-200EC 400 332 1866 280 9.9 14.2 820 1915⁄16 571⁄2 7 831⁄32 151⁄16 121⁄16 4'4" 2"
GGT-500E 2 GG-250EC 500 402 2333 350 12.0 16.4 950 235⁄16 595⁄8 8 1011⁄32 187⁄16 811⁄16 4'8" 2"
GGT-600E 2 GG-300EC 600 480 2780 417 14.3 18.4 1080 2611⁄16 595⁄8 8 121⁄32 2113⁄16 55⁄16 4'11" 2"
GGHT-750E 2 GG-375HEC 750 608 3520 529 18.1 20.6 1230 301⁄16 595⁄8 10 1323⁄32 253⁄16 115⁄16 5'2" 2"
GGHT-800E 2 GG-399HEC 798 654 3786 569 19.5 20.6 1230 301⁄16 625⁄8 10 1323⁄32 253⁄16 115⁄16 5'2" 2"
GGT-900E 3 GG-300EC 900 720 4173 626 21.5 27.6 1590 2611⁄16 595⁄8 8 121⁄32 2113⁄16 55⁄16 7'7" 2"
GGHT-1125E 3 GG-375HEC 1125 912 5286 793 27.2 30.9 1830 301⁄16 595⁄8 10 1323⁄32 253⁄16 115⁄16 7'10" 2"
GGHT-1200E 3 GG-399HEC 1197 981 5686 853 29.3 30.9 1830 301⁄16 625⁄8 10 1323⁄32 253⁄16 115⁄16 7'10" 3"
GGT-1200E 4 GG-300EC 1200 960 5560 834 28.7 36.8 2140 2611⁄16 595⁄8 8121⁄32 2113⁄16 55⁄16 10'3" 3"
GGHT-1500E 4 GG-375HEC 1500 1216 7046 1057 36.3 41.2 2440 301⁄16 595⁄8 10 1323⁄32 253⁄16 115⁄16 10'6" 3"
GGT-1500E 5 GG-300EC 1500 1200 6950 1043 35.9 46.0 2675 2611⁄16 595⁄8 8121⁄32 2113⁄16 55⁄16 12'11" 3"
GGHT-1600E 4 GG-399HEC 1596 1308 7580 1137 39.0 41.2 2440 301⁄16 625⁄8 10 1323⁄32 253⁄16 115⁄16 10'6" 3"
GGHT-1875E 5 GG-375HEC 1875 1520 8806 1321 45.4 51.5 3050 301⁄16 595⁄8 10 1323⁄32 253⁄16 115⁄16 13'2" 3"
GGHT-2000E 5 GG-399HEC 1995 1635 9473 1421 48.8 51.5 3050 301⁄16 625⁄8 10 1323⁄32 253⁄16 115⁄16 13'2" 3"
GGHT-2250E 6 GG-375HEC 2250 1824 10573 1586 54.4 61.8 3660 301⁄16 595⁄8 10 1323⁄32 253⁄16 115⁄16 15'10" 3"
GGHT-2400E 6 GG-399HEC 2394 1962 11373 1706 58.6 61.8 3660 301⁄16 625⁄8 10 1323⁄32 253⁄16 115⁄16 15'10" 3"
GGHT-2625E 7 GG-375HEC 2625 2128 12333 1850 63.5 72.1 4270 301⁄16 595⁄8 10 1323⁄32 253⁄16 115⁄16 18'6" 3"
GGHT-2800E 7 GG-399HEC 2793 2289 13266 1990 68.3 72.1 4270 301⁄16 625⁄8 10 1323⁄32 253⁄16 115⁄16 18'6" 3"
GGHT-3000E 8 GG-375HEC 3000 2432 14093 2115 72.6 82.4 4880 301⁄16 595⁄8 10 1323⁄32 253⁄16 115⁄16 21'2" 3"
GGHT-3200E 8 GG-399HEC 3192 2616 15160 2275 78.1 82.4 4880 301⁄16 625⁄8 10 1323⁄32 253⁄16 115⁄16 21'2" 3"
GGHT-3375E 9 GG-375HEC 3375 2736 15860 2379 81.7 92.7 5490 301⁄16 595⁄8 10 1323⁄32 253⁄16 115⁄16 23'10" 3"
GGHT-3600E 9 GG-399HEC 3591 2943 17060 2559 87.9 92.7 5490 301⁄16 625⁄8 10 1323⁄32 253⁄16 115⁄16 23'10" 3"
GGHT-3750E 10 GG-375HEC 3750 3040 17620 2643 90.8 103.0 6100 30
GGHT-4000E 10 GG-399HEC 3990 3270 18953 2843 97.6 103.0 6100 301⁄16 625⁄8 10 1323⁄32 253⁄16 115⁄16 26'6" 3"

I=B=R Ratings

(MBH)

Gross

Input

Output

EDR

Water‡

(Sq.Ft.)

I=B=R

Net

Output†

Boiler

Horse-

power

Water

Content

(gal.)

Ship

Wt.

Draft

Jkt.

Hood

Width

Ht.

A§

B§

1

⁄16 595⁄8 10 1323⁄32 253⁄16 115⁄16 26'6" 3"

Flue

Collar

C§

Draft
Hood

Ht.
D§

Header

to

Header

E§

Space
Btwn.
Mods.

F§

Length

with

Header

L§

Header

Size‡‡

83% Efficiency Modules

-700E 2 GG-350HEC 700 581 3368 505 17.3 20.6 1230 30

GGHT

-1050E 3 GG-350HEC 1050 872 5052 758 26 30.9 1830 30

GGHT

-1400E 4 GG-350HEC 1400 1162 6736 1010 34.7 41.2 2440 30

GGHT

-1750E 5 GG-350HEC 1750 1453 8420 1263 43.4 51.5 3050 30

GGHT

-2100E 6 GG-350HEC 2100 1743 10104 1516 52 61.8 3660 30

GGHT

-2450E 7 GG-350HEC 2450 2034 11788 1768 60.7 72.1 4270 30

GGHT

-2800E 8 GG-350HEC 2800 2324 13472 2021 69.4 82.4 4880 30

GGHT

-3150E 9 GG-350HEC 3150 2615 15157 2273 78.1 82.4 5490 30

GGHT

-3500E 10 GG-350HEC 3500 2905 16841 2526 86.7 92.7 6100 30

GGHT

1

⁄16 671⁄8 9

1

⁄16 671⁄8 9

1

⁄16 671⁄8 9

1

⁄16 671⁄8 9

1

⁄16 671⁄8 9

1

⁄16 671⁄8 9

1

⁄16 671⁄8 9

1

⁄16 671⁄8 9

1

⁄16 671⁄8 9

23

13

⁄32 253⁄16 115⁄16 5'2"

23

13

⁄32 253⁄16 115⁄16 7'10"

23

13

⁄32 253⁄16 115⁄16 10'6"

23

13

⁄32 253⁄16 115⁄16 13'2"

23

13

⁄32 253⁄16 115⁄16 15'10"

23

13

⁄32 253⁄16 115⁄16 15'10"

23

13

⁄32 253⁄16 115⁄16 21'2"

23

13

⁄32 253⁄16 115⁄16 23'10"

23

13

⁄32 253⁄16 115⁄16 26'6"

Min.

2"
2"
3"
3"
3"
3"
3"
3"
3"

LARGER SIZES,

FOR

Specify gas b

*

Net r

†

be consulted before selecting a boiler for installation having unusual piping and/or
pick-up requirements. Ratings must be reduced by 4% at 2,000 ft. elevation and
an additional 4% f

y name, "Natural" or "Propane".

atings are based on piping and pic

USE MUL

or every additional 1,000 ft. elevation over 2,000 ft.

TIPLES OF

k-up allo

THE ABO

ance of 1.15. Slant/Fin should

w

VE.

atings in square feet based on emission rate of 150 Btuh/sq. ft.

Net r

‡

er to figures 1 and 8.

Ref

§
‡‡All factory supplied headers use 3" system connections.

Modules in e

Note: For higher capacities, specify correct combination of standard Caravan

xcess of 10 should be piped in par

modules shown.

Headers sho

wn are optional.

allel in two or more batteries.

3

Figure 1:

Gas Caravan dimensions and typical piping/hot water models

Design Data
Max. ASME Working Pressure: 100 psi
Power Requirements: 120 volts, 60 HZ, .34 amps per module

4

RECOMMENDED PIPING

Figure 2. Recommended boiler piping for variable circulation

Figure 3. Supply and return piping locations

Figure 4. Instantaneous tankless coil—

two temperature with recirculation

Figure 5. Storage tank from tankless coil with recirculation

5

EQUIPMENT INCLUDED
GGT SERIES — Hot Water Models

One per module unless otherwise noted

Pre-assembled heat exchangers with built-in air separators

•
and insulated jac
Base.

•
Flue collector.

•
Gas burners, gas orifices and manifold assembly.

•
Combination gas valve including manual shut-off pressure

•
regulator.

• Pilot adjustment and automatic pilot-thermocouple safety.

• Hi-limit control.

• System pressure and temperature gauge (unmounted, one
per system).

ket.

Module pressure and temperature gauge (unmounted).

•
Module pressure relief valve (ASME) (unmounted). Specify

•
30, 50 or 100 psi.
Control header (unmounted, one per system).

•
Draft hoods (unmounted).

•

OPTIONAL EQUIPMENT

• Hot water supply and return header assemblies.

• Control panel with automatic lead lag.

• Spark ignition system.

• Vent dampers.

• External DHW heat exchanger.

Figure 6. Gas Caravan—optional header assembly for all models GGT hot water Caravan systems

*Building piping must be rigidly secured so it cannot

e where connected to headers

v

mo

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 sho

Some governing agencies do not allow compression
type couplings. Consult your local code requirements.

.

wn.

6

BOILER ROOM DESIGN

avan modular boiler systems allow better utilization of floor

Car
space and per
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. Gas-fired boiler systems consisting of 11 or more modules
should be piped in parallel in two or more batteries. Illustrated on
the following page are typical boiler room layouts and dimensional
data on the size requirements of gas-fired hot water boilers.

mit future expansion with minimum cost. Caravan

BOILER ROOM AIR SUPPLY

o ensure safe, efficient operation, the modular boiler system must

T
be supplied with sufficient air to suppor
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 INT

O THE BOILER ROOM:

t complete combustion,

Figure 7: Correct location of combustion-air supply ducts

1.

2.

3.

4.

IF BOILERS ARE INSTALLED ADJACENT TO OTHER FUEL
BURNING EQUIPMENT, THE AREA OF FREE OPENINGS
MUST BE APPROPRIATELY INCREASED TO ACCOMMODATE
THE ADDITIONAL LOAD.

wn horizontally from outdoors DIRECTLY

Air dra
through an outside wall;

the floor (below burner air inlet) and one louvered
opening near the ceiling (above the highest draft
regulator), each opening with a minimum FREE air
passage area of
system input.

Air drawn horizontally through HORIZONTAL DUCTS;

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
system input.

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.

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.

1 square inch per 4000 BTUH of total

1 square inch per 2000 BTUH of total

one louvered opening near

UNLESS PROPERLY CONTROLLED, AVOID THE USE OF
FORCED VENTILATION, SINCE IT CAN CREATE AN
UNDESIRABLE PRESSURE DIFFERENTIAL BETWEEN
BOILER ROOM AND AIR SOURCE.

7

Figure 8. Typical layouts for gas-fired systems

8

VENTING A GAS-FIRED SYSTEM

A boiler v
comb
Caravan: a draft hood for each module, a breeching manifold and a
chimney.

Draft Hood

The draft hood is part of each boiler module, although shipped in a
separate carton. It compensates for excessive draft that can be
caused by the venturi effect of winds passing over the top of the chim­ney. The dimensional relationships between the draft hood, the boiler
and surface on which the boiler is mounted, are critical. These factors
are all interdependent in allowing the draft hood to function without
moving parts. Attempts to alter these dimensions can result in unsafe
oper
Note: When mounting the modules on a r
the platf
on all sides.

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. Pitch breeching up toward chimney. Horizontal
breeching size should be maintained for the total length. Any transi­tions should be made after 4 modules. Connection should be made at
a 45° angle in the direction of the chimney. See figure 10.

Table 2. Breeching dimensions for gas-fired systems

Based on single row of modules with no elbows.
* Height measured from top of draft hood to top of chimney.
NOTE: For conditions other than those shown, consult factory, or

enting system provides an escape path for the products of

ustion. There are three major components for venting a gas-fired

ating conditions.

aised platform, be certain

orm extends past the edge of the modules at least 3 inches

GGT and GGHT series: hot water boilers.

Consists of Chimney Height*

Model No.

GGT-400E 2 GG-200EC 9" 9" 8" 8"
GGT-500E 2 GG-250EC 10" 9" 9" 8"
GGT-600E 2 GG-300EC 12" 10" 10" 9"
GGHT-700E 2 GG-350HEC 12" 12" 10" 10"
GGHT-750E 2 GG-375HEC 12" 12" 12" 10"
GGHT-800E 2 GG-399HEC 12" 12" 12" 10"
GGT-900E 3 GG-300EC 14" 12" 12" 12"
GGHT-1050E 3 GG-350HEC 14" 14" 14" 12"
GGHT-1125E 3 GG-375HEC 14" 14" 14" 12"
GGHT-1200E 3 GG-399HEC 16" 14" 14" 12"
GGT-1200E 4 GG-300EC 16" 14" 14" 12"

-1400E

GGHT
GGHT-1500E 4 GG-375HEC 16" 16" 16" 14"
GGT-1500E 5 GG-300EC 16" 16" 16" 14"

-1600E 4 GG-399HEC 18" 16" 16" 14"

GGHT
GGHT-1750E 5 GG-350HEC 18" 18" 16" 14"
GGHT-1875E 5 GG-375HEC 18" 18" 18" 16"
GGHT-2000E 5 GG-399HEC 20" 18" 18" 16"
GGHT-2100E 6 GG-350HEC 20" 18" 18" 16”
GGHT-2250E 6 GG-375HEC 20" 20" 18" 16"

-2400E

GGHT
GGHT-2450E 7 GG-350HEC 20" 20" 20" 18"
GGHT-2625E 7 GG-375HEC 22" 20" 20" 18"

-2800E

GGHT
GGHT-2800E 8 GG-350HEC 22" 22” 20” 18”

-3000E

GGHT
GGHT-3150E 9 GG-350HEC 24" 22" 22" 20"
GGHT-3200E 8 GG-399HEC 24" 22" 22" 20"

-3375E

GGHT
GGHT-3500E 10 GG-350HEC 24" 24" 22” 20"
GGHT-3600E 9 GG-399HEC 26" 24" 24" 20"
GGHT-3750E 10 GG-375HEC 26" 24" 24" 22"

-4000E 10 GG-399HEC 26" 26" 24" 22"

GGHT

National Fuel Gas Code NFP

No. of

Modules

4 GG-350HEC 16" 16" 16" 14"

6

7 GG-399HEC 22" 22" 20" 18"

8

9 GG-375HEC 24" 24" 22" 20"

Module

No.

GG-399HEC

GG-375HEC

A 54

20

Feet25Feet30Feet50Feet

20" 20" 18"

20"

22" 20"

22"

24"

Run breeching as high as clear

ertical rise of individual boiler vents. Note that this does not alter

v

ance permits to obtain maximum

chimney height (the height from hood skirt to chimney top). The
portion of chimney height rising directly above each hood is most
effective in preventing spillage. When the boiler room is in unheated
space, insulate vent pipe and breeching to maintain flue gas temper­ature and good chimney operation.

It is not permitted to lower draft
hood skirt height to achieve pitch, or to compensate for low
ceilings

breeching, a dr
are locally specified and w

For some combinations of low chimneys, ceilings and long

.

aft inducer may be needed. Inducers when required

arrantied. The breeching should extend

into, but not beyond, the chimney liner.

Chimney

Caravan gas-fired modular boilers operate efficiently with masonry or
prefabricated chimneys as well as with “Type B” or double-walled
metal vent pipe. This latter type of chimney construction is generally
the least expensive. Chimney height is usually governed by the
building height and the size of the boilers (see Table 1). However, the
chimney should be high enough to minimize the effects of turbulent
winds and pressure common near roof-top obstruction. A vent cap
should be used where permitted for additional protection against
adverse wind conditions and precipitation. The National Board of Fire
Underwriters recommend that the chimney should extend at least 3
feet above the roof and be 2 feet higher than any obstruction within 10
feet.

Sizing Horizontal Breeching Connectors and Chimneys for Gas­Fired Systems

Horizontal breeching connectors shall be constant sized.The chimney
and the horizontal breeching connector are sized using Table 2.
When there are multiple banks of boilers, the horizontal breeching
connector for each bank is sized using Table 2. To size the common
horizontal breeching connector, add up the total input and refer to
Table 2 to size.

The minimum chimney opening will be equal to the size of the largest
horizontal breeching section connected to it.

Horizontal Breeching Connector Length

The MAXIMUM length of the horizontal breeching connector length
between the chimney and the closest boiler shall

NOT be longer than
12 inches per inch of horizontal breeching connector diameter, i.e. if
the horizontal breeching connector is 16" D., the

MAXIMUM length

from the chimney to the first boiler would be 16" x 12" or 192 inches.

MINIMUM length shall be 12 inches regardless of the horizontal

The
breeching connector diameter

. See figure 9.

9

Connector Rise: Connector rise is the length of the pipe connecting the top
of the draft hood to the system breeching above. The diameter of this pipe
varies depending upon BTU input, chimney height and the length of the
connector. Fig.9 (Dim. “B”) shows the location of this pipe in a typical appli­cation. Table 2a depicts the proper diameter (Dim. “C”) of the connector rise
depending upon its total length (top of the dr

ve).

abo

Vent Connector Diameters (20’ chimney*)

Model

Flue Outlet

Size

3' High

aft hoods to the breeching

Connector

2' High

1' High

Figure 9. Connector rise

GG-200C

7” 7” 7” 8”
GG-250C 8” 8” 8” 10”
GG-300C 8” 8” 10” 10”
GG-350H 9” 9” 10” 12”
GG-375-HC 10” 10” 10” 12”
GG-399-HC 10” 10” 12” 12”

Based on single row of modules with no elbows.

TE: For conditions other than those shown, consult factory, or National Fuel

NO

Gas Code NFP

A 54

Figure 10. Suggested venting system constructions

10

GAS PIPING

This section contains sizing and construction recommendations

or fuel supply piping to Caravan gas-fired modular boiler

f
systems. Gas-fired equipment must conform not only to codes of
local regulator
may be imposed by the utility or gas supplier. Therefore, the
following information should be considered only as a guideline.

Figure 11 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 valve sediment trap, gas header pipe and
drip legs on individual boilers.

y agencies, but also to additional specifications that

Individual gas lines to individual boiler modules should be

3

⁄4"
diameter. Size of gas main and header pipes depends on volume
of gas required and acceptable pressure drop between meter and
modules’ gas regulator valves. Minimum pressure required at each
valve is 5 inches of water column for natural gas and 11 inches for
propane gas, measured while all boilers and other gas-fired
equipment on the same meter are firing. Small variations in gas
flow can be compensated for by adjusting gas regulator valves.
However, final pressure of gas header must vary no more than
+ 0.3 in. of water column.

Table 3: Gas consumption rate

hot water boilers only

Gas

Model No.

GGT-400E 400
GGT-500E 500
GGT-600E 600
GGHT-700E 700
GGHT-750E 750
GGHT-800E 798
GGT-900E 900
GGHT-1050E 1050
GGHT-1125E 1125
GGHT-1200E 1197
GGT-1200E 1200
GGHT-1400E 1400
GGHT-1500E 1500
GGT-1500E 1500
GGHT-1600E 1596
GGHT-1750E 1750
GGHT-1875E 1875
GGHT-2000E 1995
GGHT-2100E 2100
GGHT-2250E 2250
GGHT-2400E 2394
GGHT-2450E 2450
GGHT-2625E 2625
GGHT-2800E 2793
GGHT-2800E 2800
GGHT-3000E 3000
GGHT-3150E 3150
GGHT-3200E 3192
GGHT-3375E 3375
GGHT-3500E 3500
GGHT-3600E 3591
GGHT-3750E 3750
GGHT-4000E 3990

Consumption In CFH

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 4, 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 3 in hot water

systems.

d. Multiply the system total hourly gas consumption by flow correction value from

Table 5.
e. Locate system’s total equivalent pipe length in right column of Table 6.
f. Move vertically to the system’s corrected flow rate calculated in step (c). If this value

falls between two of those listed, select larger value.
g. From this point move horizontally to the left column and read suggested pipe

diameter for gas main.

Table 4: Equivalent linear length in feet of standard iron pipe fittings for natural gas

Pipe

Size

Inches Standard

Elbow Valve

Medium

Sweep

Long

Sweep Gate Globe Angle

Return

Bend

Side

Outlet

Tee

1/2 0.84 0.52 0.41 0.031 2.50 1.12 1.25 1.66

3/4 1.17 0.73 0.57 0.044 3.50 1.84 1.75 2.33

1 1.57 0.98 0.77 0.057 4.68 2.11 2.34 3.11

1-1/4

2.19

1.37

1.07

0.082 6.54 2.94 3.27 4.35

1-1/2 2.63 1.64 1.29 0.098 7.84 3.52 3.92 5.21

2
3

3.55

5.72

2.23

3.59

1.74 1.320 10.60 4.77 5.30 7.05

2.81

2.130

17.08

7.69

8.84 11.40

ypical gas suppl

Figure 11.

T

y line installation

11

able 5. Characteristics of various fuel gases

T

Type

of Gas

al 1000 Btu 1.00

Natur

Heating

Valve*†

Flow

Correction

Factor

Propane 2500 Btu 1.10

* per cubic f
† Consult fuel supplier for actual BTU value.

Table 6. Gas main sizing guide

Iron Pipe

oot

Nominal

Size

Inches

Internal

Diameter

Inches

10 20 30 40 50 60 70

Equivalent

Length of Pipe, Feet

1/4 .364 32 22 18 15 14 12 11
3/8 .493 72 49 40 34 30 27 25
1/2 .622 132 92 73 63 56 50 46
3/4 .824 278 190 152 130 115 105 96

1 1.049 520 350 285 245 215 195 180
1 1/4 1.380 1,050 730 590 500 440 400 370
1 1/2 1.610 1,600 1,100 890 760 670 610 560

2 2.067 3,050 2,100 1,650 1,450 1,270 1,150 1,050
2 1/2 2.469 4,800 3,300 2,700 2,300 2,000 1,850 1,700

3 3.068 8,500 5,900 4,700 4,100 3,600 3,250 3,000

4 4.026 17,500 12,000 9,700 8,300 7,400 6,800 6,200

80 90 100 125 150 175 200

1/4 .364 11 10 9 8 8 7 6
3/8 .493 23 22 21 18 17 15 14
1/2 .622 43 40 38 34 31 28 26
3/4 .824 90 84 79 72 64 59 55

1 1.049 170 160 150 130 120 110 100
1 1/4 1.380 350 320 305 275 250 225 210
1 1/2 1.610 530 490 460 410 380 350 320

2 2.067 990 930 870 780 710 650 610
2 1/2 2.469 1,600 1,500 1,400 1,250 1,130 1,050 980

3 3.068 2,800 2,600 2,500 2,200 2,000 1,850 1,700

4 4.026 5,800 5,400 5,100 4,500 4,100 3,800 3,500

Maximum capacity of pipe in cubic
feet of gas per hour for gas pres­sures of 0.5 psig or less and a
pressure drop of 0.3 inch water
column (based on a 0.60 specific
gravity gas).

12

CONTROLS

THE BOILER STAGING CONCEPT

The heart of the Caravan boiler plant is a temperature-actuated
control system that automatically stages only those boiler
modules needed to meet the heating demand in a given period,

y conserving fuel.

thereb

In a staging control system, each stage ordinarily activates one
boiler module. With appropriate wiring, multiple modules can be

rouped within a stage.

g

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
continuously, thereby performing at peak efficiency. For example,
in a 10 module boiler system, with the heating load at 61% of
capacity
efficiency
se
"off
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 by more than a portion
of one module, regardless of the load.

The Caravan control system automatically compensates for
seasonal temperature changes. It energizes more or fewer
modules depending on changes of outside temperature, system
water temperature, or both. Modules save energy by operating in
long cycles at full-rated output and maximum efficiency.

, six of the modules operate continuously at peak

. Fractional heating requirements are supplied by the

venth "cycling" module, while the remaining three modules are

." This is in contrast to a single large central boiler that simply

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 building temperature control. They do not replace zoning
the system or the thermostats that control these zones.

SC-3 Control

The SC-3 control allo
Generally each stage controls 1 module. However, it is possible to

e more than 1 module activ

v

ha

Standard programmable features include: system activation or
de-activ
supply w
temper
outdoor temperature and indoor design temperatures.

The vie
outdoor air temper
target supply water temperature and running time for each stage.

ation based on outdoor temper

ater temper

ature; adjustable delay between stages; adjustable

w men

ws up to 3 stages in a Car

ated with each stage.

ature;

adjustable design target supply water

ature;

u on the control includes error messages

ature, actual supply water temperature,

avan system.

um target

minim

, actual

This control can be programmed as follows:

1. Outdoor reset: The supply water temperature is
automatically adjusted up or do
temperature. The control automatically controls the

umber of modules required to maintain required supply

n
water temperature.
Setpoint temperature: The control can be programmed

2.
to maintain a set supply water temperature. The control
automatically controls the number of modules activated to
maintain the setpoint temperature.

SC-9 Control

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.

Standard programmable features include: system activation or
de-activation based on outdoor temperature; minimum target
supply water temperature; adjustable design target supply water
temperature; 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
outdoor 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 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.

Setpoint temperature: The control maintains a set supply

2.
water temperature. The control activates only the number
of stages required to maintain the setpoint temperature.
Setpoint temperature may be used for a Caravan system
that is dedicated f

3.

Domestic hot water: The domestic hot water controls
override the SC-9 control for only those modules used to
heat the domestic hot w

ater are isolated from space heating system until

hot w
demand f
not used for domestic hot water heating remain under
control of SC-9 control.

Slant/Fin off
external tankless heaters as options for use with the SC-9
control.

or domestic hot water is satisfied. The modules

or use as v

ater

ers domestic hot w

wn based on outdoor

olume w

The modules f

.

ater heating.

or domestic

ater control packages and

13

BILL OF MATERIALS FOR SC SERIES CONTROLLERS

Material List for SC-3

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

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

• 1 Outdoor sensor (part # 339-070)

• 2 Universal sensors (part # 339-071)

- 1 to be used as supply water sensor

- 1 can be used as return water sensor

• 2 Plastic tie straps

Other Options

• 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 cast iron 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 contractor.

include:

14

FIELD WIRING AT MODULES

15

SC-3 SYSTEM WIRING DIAGRAM

16

SC-3 LADDER WIRING DIAGRAM

17

SC-9 SPACE HEATING WIRING DIAGRAM

18

SC-9 SPACE HEATING LADDER WIRING DIAGRAM

19

SC-9 SPACE AND DOMESTIC HOT WATER WIRING DIAGRAM

20

SC-9 SPACE AND DOMESTIC HOT WATER LADDER WIRING DIAGRAM

21

Slant/Fin

Limited Five-Year Warranty

for Caravan Modular and Individual Commercial Application

Cast-iron Hot Water Boilers in Space Heating Applications.

WARRANTY INCLUDES:
FIRST YEAR:

warranty service procedure, for a period of one year after
or

iginal installation, of all parts found to be defectively

manufactured.

W

ARRANTY INCLUDES:

SECOND THROUGH FIFTH YEAR:

for the second through fifth year after original installation, of
cast iron heat exchanger found to be defectively manufac­tured, at no cost for the replacement part. The repaired or
exchanged part will be warranted for only the unexpired
portion of the original warranty.

This warranty extends only to boilers in space heating
applications. See “Additional Warranty Terms” section for
more details.

Warranty extends only to boilers which have been properly
installed, operated and maintained in accordance with
Slant/Fin installation instructions and all applicable codes.
Warranty applies only if the boiler has remained at all times
in the location at which it was originally installed. Slant/Fin
makes no express warranties other than the warranties
contained herein.

WARRANTY EXCLUDES:

All labor charges incurred by any person in connection with
the examination, removal, and repair of parts claimed to be
defective and the installation of replacement parts.

Repair or replacement in accordance with

Repair or replacement

AFTER FIRST YEAR, WARRANTY EXCLUDES:

All boiler components other than a cast-iron heat exchanger,
such as, sheet metal base, jacket, insulation, combustion
chamber, tankless heater exhaust and air inlet piping, burner
enclosure, mixing elbow, gas and air orifice, blower assem­bly, air filter and electrical and mechanical components
furnished to Slant/Fin by other manufacturers, such as
pumps, relays, controls, gauges, etc.

PROCEDURE FOR WARRANTY SERVICE:

or warranty service, provide the person who installed your

F
Slant/Fin boiler with the following information: boiler model
number and serial number (from the boiler rating plate) and
the date of installation. That person will notify the Slant/Fin
wholesaler from whom the boiler was purchased.

Part(s) claimed to be defective must be returned through
trade channels and replacement part(s) will, if warranty
conditions are met, be provided by Slant/Fin through the
wholesaler.

If there are any questions about the coverage of this
warranty, please contact Slant/Fin at the address shown
below.

LIMITATIONS ON IMPLIED WARRANTIES AND
DAMAGES:

Slant/Fin assumes no liability for damages or unsatisfactory
performance of any kind which is a result of improper
installation.

The part claimed to be defective shall be returned to
Slant/Fin. The cost of shipment to Slant/Fin is borne by the
consumer.

Damage caused by water that contains excessive lime,
calcium, or other contaminants.

Boilers operated with combustion air that may be
contaminated by chemicals or improper fuel additives.

Improper b
maintenance procedures.

NOTE:

application that causes significant quantities of fresh make
up water to enter the system is not permitted. Such
applications can be met with a heat exchanger that will
maintain the boilers in a closed system.

urner adjustments, control settings or

Boilers are to be used in closed systems

y

An

.

Technical Service Department

Slant/Fin Corporation, 100 Forest Drive at East Hills, Greenvale, N. Y. 11548 • [phone]

Slant/Fin's sole obligation in the event of a breach of any
implied w
warranties of merchantability and fitness for a particular
pur
warranties are limited in duration to the period of time after
the date of or

This warranty does not cover claims for incidental or
consequential damages resulting from a breach of any
express or implied warranty or any other reason.

Some states do not allo
warranty lasts or the exclusion or limitation of incidental or
consequential damages. So the above limitation or
e

THIS
AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH
VARY FROM STATE TO STATE.

arranty (including, but not limited to, implied

pose) is limited to repair or replacement, and all such

.

e

iginal installation as stated abo

w limitations on how long an implied

xclusion ma

y not apply to y

WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS

ou.

v

22

CARAVAN SYSTEM RATING PLATE

System rating plate format for Caravan modular boiler system.

System rating plates are available upon request using the form on the back cover.

REQUEST FOR CARAVAN SYSTEM RATING PLATE

Each individual Caravan module is shipped with a rating
plate bearing the model, serial number, capacities and
certifications for that module. A modular boiler system is a
single boiler. To meet local requirements, a system rating
plate will be issued b
pro

vide the information indicated on this page.

y Slant/Fin upon request. Just

Slant/Fin Tech

Service

FAX THIS REQUEST TO: 516-484-6958

PHONE: [phone]

Requested by:

Mail to:

PLEASE USE CARE TO MAKE SURE THE PROPER SYSTEM MODEL IS INDICATED

Type of System:

Phone:

Phone:

NOTE:

INDICATE ACCURATELY

Some model numbers are similar, such as GGT-600 and GGT-600E etc.

COMPLETE WITH LETTER SUFFIX.

INCLUDE ALL LETTERS AND ZEROS, ENTER ALL

USE A SEPARATE FORM FOR EACH SYSTEM

Gas

Oil

Water

Steam

BE ACCURATE!

Natural Gas

Propane

Dual Fuel

Required

Required

INFORMATION ASKED FOR!

INDICATE SYSTEM MODEL
NUMBER BELOW:

INDICATE SERIAL NUMBERS OF INDIVIDUAL MODULES (Please write legibly)

System serial number assigned Done by

DO NO

FOR

WRITE BELOW THIS LINE

T

SLANT/FIN USE ONL

SLANT/FIN CORPORATION, Greenvale, N.Y. 11548 • Phone: [phone]

F

AX:

Y

[phone]

• Canada:

Slant/Fin

TD/L

L

TEE

, Mississauga, Ontar

www.slantfin.com

io