Slant/Fin CARAVAN GGT-600E User guide

HOT WATER/GAS Modular Boilers
A LICATION GUIDE
ublication No. CG-10-HWG
Printed in the U.S.A. 1212
www.slantfin.com
Guidelines for the design, purchase and installation of Slant/Fin Caravan gas-fired, hot water modular boiler systems.
®
CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Ratings and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,3
Recommended Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Optional factory supply and return headers . . . . . . . . . . . . . .5
Boiler room design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Boiler room air supply requirements . . . . . . . . . . . . . . . . . . . .6
Typical layouts for gas-fired systems . . . . . . . . . . . . . . . . . . .7
Venting a gas-fired system . . . . . . . . . . . . . . . . . . . . . . . . . .8,9
Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10,11
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11,12
SC- control bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . .12
ield wiring at modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
SC-3 system wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
SC-3 ladder wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
SC-9 space heating wiring . . . . . . . . . . . . . . . . . . . . . . . . . .16
SC-9 space heating ladder wiring . . . . . . . . . . . . . . . . . . . . .17
SC-9 space and domestic hot water wiring . . . . . . . . . . . . .18
SC-9 space and domestic hot water ladder wiring . . . . . . . .19
Caravan warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21,22
Request for Caravan rating plate . . . . . . . . . . . . . . . . . . .23,24
CODES AND STANDARDS
All Caravan installations must comply to local codes or, in the
absence of local codes, to the National uel 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/ in Instruction Book
publication no. GG-100-40 latest edition.
All electrical wiring is to be done in accordance with the National
Electrical Code ANSI/N PA 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.
Many state and local codes require intermittent ignition devices for
gas boilers. Please specify if necessary.
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.
resh 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.
LOCAL CODE A ROVALS
New ork City:
GGT and GGHT Caravan Modules - MEA 283-93-E Vol. II
Slant/ in vent damper NYS approval No. 8859
Pennsylvania:
Caravan boilers are approved in Pennsylvania by PA Cert. 174-BT-S

2
* Specify gas by name, "Natural" or "Propane".
† Net ratings are based on piping and pick-up allowance of 1.15. Slant/ in should
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% for every additional 1,000 ft. elevation over 2,000 ft.
‡ Net ratings in square feet based on emission rate of 150 Btuh/sq. ft.
§ Refer to figures 1 and 8. Headers shown are optional.
‡‡All factory supplied headers use 3" system connections.
Modules in excess of 10 should be piped in parallel in two or more batteries.
Note: or higher capacities, specify correct combination of standard Caravan
modules shown.
FOR LARGER SIZES, USE MULTI LES OF THE ABOVE.
Table 1: Gas Caravan ratings and dimension/hot water model—GGT Series (100 psi maximum working pressure)
GGT-600E 2 GG-300ES 600 486 2814 422 14.5 81.10 18.4 1080 2611⁄16 595⁄88 121⁄32 2113⁄16 55⁄16 4'11" 2"
GGHT-700E 2 GG-350HES 700 570 3306 496 17.0 81.40 20.6 1230 301⁄16 671⁄89 1323⁄32 253⁄16 115⁄16 5'2" 2"
GGHT-750E 2 GG-375HES 750 606 3506 526 18.1 80.90 20.6 1230 301⁄16 595⁄810 1323⁄32 253⁄16 115⁄16 5'2" 2"
GGHT-800E 2 GG-399HES 798 644 3734 560 19.2 80.60 20.6 1230 301⁄16 665⁄810 1323⁄32 253⁄16 115⁄16 5'2" 2"
GGT-900E 3 GG-300ES 900 729 4221 633 21.8 81.10 27.6 1590 2611⁄16 595⁄88 121⁄32 2113⁄16 55⁄16 7'7" 2"
GGHT-1050E 3 GG-350HES 1050 855 4959 744 25.5 81.40 30.9 1830 301⁄16 671⁄89 1323⁄32 253⁄16 115⁄16 7'10" 2"
GGHT-1125E 3 GG-375HES 1125 909 5259 789 27.2 80.90 30.9 1830 301⁄16 595⁄810 1323⁄32 253⁄16 115⁄16 7'10" 2"
GGHT-1200E 3 GG-399HES 1197 966 5601 840 28.9 80.60 30.9 1830 301⁄16 665⁄810 1323⁄32 253⁄16 115⁄16 7'10" 3"
GGT-1200E 4 GG-300ES 1200 972 5628 844 29.0 81.10 36.8 2140 2611⁄16 595⁄88 121⁄32 2113⁄16 55⁄16 10'3" 3"
GGHT-1400E 4 GG-350HES 1400 1140 6612 992 34.1 81.40 41.2 2440 301⁄16 671⁄89 1323⁄32 253⁄16 115⁄16 10'6" 3"
GGHT-1500E 4 GG-375HES 1500 1212 7012 1052 36.2 80.90 41.2 2440 301⁄16 595⁄810 1323⁄32 253⁄16 115⁄16 10'6" 3"
GGT-1500E 5 GG-300ES 1500 1215 7035 1055 36.3 81.10 46.0 2675 2611⁄16 595⁄88 121⁄32 2113⁄16 55⁄16 12'11" 3"
GGHT-1600E 4 GG-399HES 1596 1288 7468 1120 38.5 80.60 41.2 2440 301⁄16 665⁄810 1323⁄32 253⁄16 115⁄16 10'6" 3"
GGHT-1750E 5 GG-350HES 1750 1425 8265 1240 42.6 81.40 51.5 3050 301⁄16 671⁄89 1323⁄32 253⁄16 115⁄16 13'2" 3"
GGHT-1875E 5 GG-375HES 1875 1515 8765 1315 45.3 80.90 51.5 3050 301⁄16 595⁄810 1323⁄32 253⁄16 115⁄16 13'2" 3"
GGHT-2000E 5 GG-399HES 1995 1610 9333 1400 48.1 80.60 51.5 3050 301⁄16 665⁄810 1323⁄32 253⁄16 115⁄16 13'2" 3"
GGHT-2100E 6 GG-350HES 2100 1710 9918 1488 51.1 81.40 61.8 3660 301⁄16 671⁄89 1323⁄32 253⁄16 115⁄16 15'10" 3"
GGHT-2250E 6 GG-375HES 2250 1818 10518 1578 54.3 80.90 61.8 3660 301⁄16 595⁄810 1323⁄32 253⁄16 115⁄16 15'10" 3"
GGHT-2400E 6 GG-399HES 2394 1932 11202 1680 57.7 80.60 61.8 3660 301⁄16 665⁄810 1323⁄32 253⁄16 115⁄16 15'10" 3"
GGHT-2450E 7 GG-350HES 2450 1995 11571 1736 59.6 81.40 72.1 4270 301⁄16 671⁄89 1323⁄32 253⁄16 115⁄16 18'6" 3"
GGHT-2625E 7 GG-375HES 2625 2121 12271 1841 63.4 80.90 72.1 4270 301⁄16 595⁄810 1323⁄32 253⁄16 115⁄16 18'6" 3"
GGHT-2800E 7 GG-399HES 2793 2254 13069 1960 67.3 80.60 72.1 4270 301⁄16 665⁄810 1323⁄32 253⁄16 115⁄16 18'6" 3"
GGHT-2800AE 8 GG-350HES 2800 2280 13224 1984 68.1 81.40 82.4 4880 301⁄16 671⁄89 1323⁄32 253⁄16 115⁄16 21'2" 3"
GGHT-3000E 8 GG-375HES 3000 2424 14024 2104 72.4 80.90 82.4 4880 301⁄16 595⁄810 1323⁄32 253⁄16 115⁄16 21'2" 3"
GGHT-3150E 9 GG-350HES 3150 2565 14877 2232 76.6 81.40 82.4 5490 301⁄16 671⁄89 1323⁄32 253⁄16 115⁄16 23'10" 3"
GGHT-3200E 8 GG-399HES 3192 2576 14936 2240 77.0 80.60 82.4 4880 301⁄16 665⁄810 1323⁄32 253⁄16 115⁄16 21'2" 3"
GGHT-3375E 9 GG-375HES 3375 2727 15777 2367 81.5 80.90 92.7 5490 301⁄16 595⁄810 1323⁄32 253⁄16 115⁄16 23'10" 3"
GGHT-3500E 10 GG-350HES 3500 2850 16530 2480 85.1 81.40 92.7 6100 301⁄16 671⁄89 1323⁄32 253⁄16 115⁄16 26'6" 3"
GGHT-3600E 9 GG-399HES 3591 2898 16800 2520 86.6 80.60 92.7 5490 301⁄16 665⁄810 1323⁄32 253⁄16 115⁄16 23'10" 3"
GGHT-3750E 10 GG-375HES 3750 3030 17530 2630 90.5 80.90 103.0 6100 301⁄16 595⁄810 1323⁄32 253⁄16 115⁄16 26'6" 3"
GGHT-4000E 10 GG-399HES 3990 3220 18670 2800 96.2 80.60 103.0 6100 301⁄16 665⁄810 1323⁄32 253⁄16 115⁄16 26'6" 3"
No.of
Htg.
Mod.
Module
Model
Number
CSA
Input
Gross
Output
EDR
Water‡
(Sq.Ft.)
AHRI
Net
Output†
Boiler
Horse-
power
Water
Content
(gal.)
Thermal
EFF.
%
Ship
Wt.
Jkt.
Width
A§
Draft
Hood
Ht.
B§
Flue
Collar
C§
Draft
Hood
Ht.
D§
Header
to
Header
E§
Space
Btwn.
Mods.
F§
Length
with
Header
L§
Min.
Header
Size‡‡
Consists of
Ratings
Model No.
INTRODUCTION
This Caravan application manual is intended to simplify the selection
and application of Slant/ in 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 any additional information is required, contact your local
wholesaler, Slant/ in sales representative, or the Slant/ in factory.
Due to design flexibility of a Caravan modular boiler system, BTU
input capacities are unlimited.
A. 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.
B. Faster, easier installation - modules are completely factory
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
separately for mounting directly on each module.
D. Fast domestic hot water recovery - Caravan offers an external
heat exchanger of the positive circulating type.

3
Design Data
Max. ASME Working Pressure: 100 psi
Power Requirements: 120 volts, 60 HZ, .34 amps per module
Figure 1: Gas Caravan dimensions and typical piping/hot water models

4
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
RECOMMENDED I ING

5
EQUI MENT INCLUDED
GGT SERIES — Hot Water Models
One per module unless otherwise noted
• Pre-assembled heat exchangers with built-in air separators
and insulated jacket.
• Base.
• lue collector.
• Gas burners, gas orifices and manifold assembly.
• Combination gas valve including manual shut-off pressure
regulator.
• Hi-limit control.
• System pressure and temperature gauge (unmounted, one
per system).
• 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).
O TIONAL EQUI MENT
• 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
move where connected to headers.
NOTE:
Shown reverse return (Preferred). or 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 requirements.

6
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. 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.
BOILER ROOM AIR SU LY
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.
or additional information, not listed below, see ANSI,Z223.1,
section 5.3.3.
INSTALLATION IN ENCLOSED BOILER ROOM REQUIRES
TWO UNOBSTRUCTED OPENINGS OR PASSAGE O
AIR INTO THE BOILER ROOM:
1. Air drawn horizontally from outdoors DIRECTLY
through an outside wall; one louvered opening near
the floor (below burner air inlet) and one louvered
opening near the ceiling (above the highest draft
regulator), each opening with a minimum REE air
passage area of 1 square inch per 4000 BTUH of total
system input.
2. 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 REE 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 REE 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 REE air passage area of
1 square inch per 1000 BTUH of total system input.
I BOILERS ARE INSTALLED ADJACENT TO OTHER UEL
BURNING EQUIPMENT, THE AREA O REE OPENINGS
MUST BE APPROPRIATELY INCREASED TO ACCOMMODATE
THE ADDITIONAL LOAD.
UNLESS PROPERLY CONTROLLED, AVOID THE USE O
ORCED VENTILATION, SINCE IT CAN CREATE AN
UNDESIRABLE PRESSURE DI ERENTIAL BETWEEN
BOILER ROOM AND AIR SOURCE.
Figure 7: Correct location of combustion-air supply ducts

7
Figure 8. Typical layouts for gas-fired systems

8
VENTING A GAS-FIRED SYSTEM
A boiler venting system provides an escape path for the products of
combustion. There are three major components for venting a gas-fired
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 chim-
ney. 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
operating conditions.
Note: When mounting the modules on a raised platform, be certain
the platform extends past the edge of the modules at least 3 inches
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 construct-
ed 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 transi-
tions should be made after 4 modules. Connection should be made at
a 45° angle in the direction of the chimney. See figure 10.
Run breeching as high as clearance permits to obtain maximum
vertical rise of individual boiler vents. Note that this does not alter
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 temper-
ature and good chimney operation. It is not permitted to lower draft
hood skirt height to achieve pitch, or to compensate for low
ceilings. or some combinations of low chimneys, ceilings and long
breeching, a draft inducer may be needed. Inducers when required
are locally specified and warrantied. 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 ire
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 Gas-
Fired 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.
The MINIMUM length shall be 12 inches regardless of the horizontal
breeching connector diameter. See figure 9.
GGT-600E 2 GG-300ES 12" 10" 10" 9"
GGHT-700E 2 GG-350HES 12" 12" 10" 10"
GGHT-750E 2 GG-375HES 12" 12" 12" 10"
GGHT-800E 2 GG-399HES 12" 12" 12" 10"
GGT-900E 3 GG-300ES 14" 12" 12" 12"
GGHT-1050E 3 GG-350HES 14" 14" 14" 12"
GGHT-1125E 3 GG-375HES 14" 14" 14" 12"
GGHT-1200E 3 GG-399HES 16" 14" 14" 12"
GGT-1200E 4 GG-300ES 16" 14" 14" 12"
GGHT-1400E 4 GG-350HES 16" 16" 16" 14"
GGHT-1500E 4 GG-375HES 16" 16" 16" 14"
GGT-1500E 5 GG-300ES 16" 16" 16" 14"
GGHT-1600E 4 GG-399HES 18" 16" 16" 14"
GGHT-1750E 5 GG-350HES 18" 18" 16" 14"
GGHT-1875E 5 GG-375HES 18" 18" 18" 16"
GGHT-2000E 5 GG-399HES 20" 18" 18" 16"
GGHT-2100E 6 GG-350HES 20" 18" 18" 16”
GGHT-2250E 6 GG-375HES 20" 20" 18" 16"
GGHT-2400E 6 GG-399HES 20" 20" 20" 18"
GGHT-2450E 7 GG-350HES 20" 20" 20" 18"
GGHT-2625E 7 GG-375HES 22" 20" 20" 18"
GGHT-2800E 7 GG-399HES 22" 22" 20" 18"
GGHT-2800AE 8 GG-350HES 22" 22” 20” 18”
GGHT-3000E 8 GG-375HES 24" 22" 22" 20"
GGHT-3150E 9 GG-350HES 24" 22" 22" 20"
GGHT-3200E 8 GG-399HES 24" 22" 22" 20"
GGHT-3375E 9 GG-375HES 24" 24" 22" 20"
GGHT-3500E 10 GG-350HES 24" 24" 22” 20"
GGHT-3600E 9 GG-399HES 26" 24" 24" 20"
GGHT-3750E 10 GG-375HES 26" 24" 24" 22"
GGHT-4000E 10 GG-399HES 26" 26" 24" 22"
Model No.
No. of
Modules
Module
No.
Consists of Chimney Height*
20
Feet
25
Feet
30
Feet
50
Feet
Based on single row of modules with no elbows.
* Height measured from top of draft hood to top of chimney.
NOTE: or conditions other than those shown, consult factory, or
National uel Gas Code N PA 54
Table 2. Breeching dimensions for gas-fired systems
GGT and GGHT series: hot water boilers.

9
Figure 9. Connector rise
Figure 10. Suggested venting system constructions
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. ig.9 (Dim. “B”) shows the location of this pipe in a typical
application. Table 2a depicts the proper diameter (Dim. “C”) of the connec-
tor rise depending upon its total le
ngth (top of the draft hoods to the
breeching above).
Based on single row of modules with no elbows.
NOTE: or conditions other than those shown, consult factory, or National uel
Gas Code N PA 54.
NOTE: “E” dimensions (from table 2), when designing breeching dia. is the
same as chimney dia.
Table 2A.
Vent Connector Diameters (20 ft. chimney “F” dim)
Model
Flue Outlet Size Connector Rise “B”
“A” 3' High 2' High 1' High
“C” “C” “C”
GG300ES 8” 8” 10” 10”
GG350HES 9” 9” 10” 12”
GG375HES 10” 10” 10” 12”
GG399HES 10” 10” 12” 12”

10
Gas Main Sizing
To determine the correct pipe diameter for the gas main serving a specific Caravan
system, proceed as follows:
a. ollow 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. ind 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. rom this point move horizontally to the left column and read suggested pipe
diameter for gas main.
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-2800AE 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
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 3.55 2.23 1.74 1.320 10.60 4.77 5.30 7.05
3 5.72 3.59 2.81 2.130 17.08 7.69 8.84 11.40
Model No.
Gas
Consumption In CFH
Table 3: Gas consumption rate
hot water boilers only
Table 4: Equivalent linear length in feet of standard iron pipe fittings for natural gas
Figure 11. Typical gas supply line installation
Pipe
Size
Inches Standard
Medium
Sweep
Long
Sweep Gate Globe Angle
Return
Bend
Side
Outlet
Tee
Elbow alve
GAS I ING
This section contains sizing and construction recommendations
for fuel supply piping to Caravan gas-fired modular boiler
systems. 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
following information should be considered only as a guideline.
igure 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.
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.

10 20 30 40 50 60 70
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 9 887 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
11
Table 5. Characteristics of various fuel gases Table 6. Gas main sizing guide
Natural 1000 Btu 1.00
Propane 2500 Btu 1.10
Type
of Gas
Heating
alve*†
Flow
Correction
Factor
* per cubic foot
† Consult fuel supplier for actual BTU value.
Nominal
Iron Pipe
Size
Inches
Internal
Diameter
Inches
Equivalent
Length of Pipe, Feet
Max mum capac ty of p pe n cub c
feet of gas per hour for gas pres-
sures of 0.5 ps g or less and a
pressure drop of 0.3 nch water
column (based on a 0.60 spec f c
grav ty gas).
CONTROLS
THE BOILER STAGING CONCE T
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,
thereby conserving fuel.
In a staging control system, each stage ordinarily activates one
boiler 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
continuously, thereby performing at peak efficiency. or example,
in a 10 module boiler system, with the heating load at 61% of
capacity, six of the modules operate continuously at peak
efficiency. ractional heating requirements are supplied by the
seventh "cycling" module, 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 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.
CONTROL SYSTEM SELECTION
Slant/ in offers two controls to step fire a hot water Caravan sys-
tem. The SC-3 and SC-9 controls fulfill a wide range of applica-
tions. 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 Cont ol
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.
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 temperature and indoor design temperatures.
The view menu on the control includes error messages, actual
outdoor air temperature, actual supply water temperature,
target supply water temperature and running time for each stage.

12
This 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 Cont ol
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 sup-
ply water temperature; adjustable design target supply water tem-
perature; 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 cir-
culator 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 dif-
ference 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.
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 may be used for a 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/ in offers domestic hot water control packages and
external tankless heaters as options for use with the SC-9
control.
BILL OF MATERIALS FOR SC SERIES CONTROLLERS
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 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.
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

13
FIELD WIRING AT MODULES

14
SC-3 SYSTEM WIRING DIAGRAM

15
SC-3 LADDER WIRING DIAGRAM

16
SC-9 S ACE HEATING WIRING DIAGRAM

17
SC-9 S ACE HEATING LADDER WIRING DIAGRAM

18
SC-9 S ACE AND DOMESTIC HOT WATER WIRING DIAGRAM

19
SC-9 S ACE AND DOMESTIC HOT WATER LADDER WIRING DIAGRAM

20
BOILER WARRANTIES
Lifetime Limited Warranty
for Residential Cast-iron Hot Water
Boilers in Ho sehold Use
Gas Models: Sentinel, Sentry, Galaxy and Victory
Oil Models:Intrepid, Liberty, Liberty II, XL-2000, EC
Series
Electric Models:Monitron
FIRST-YEAR WARRANTY INCLUDES:
Repair or replacement for a period of one year after original installa-
tion of all parts found to be defectively manufactured.
LIFETIME LIMITED WARRANTY OF CAST-IRON SECTIONS is
effective for as long as the boiler is owned by the original purchaser
or for 25 years, whichever time period is longer. The warranty
includes repair or replacement of cast iron sections found to be
defectively manufactured, at a cost to consumer equal to the per-
centage indicated below of the manufacturer's then list price for the
replacement parts:
This warranty extends only to boilers in household use.
See “Additional Warranty Terms” section for more details.
Limited Ten-Year Warranty
for Residential Application Cast-iron
Steam Boilers
This warranty extends only to steam boilers and Jaguars in house-
hold use in buildings with one or two family dwelling units and which
have been properly installed by a qualified heating contractor whose
principal occupation is in the installation of heating equipment. Also,
this warranty applies only to the first retail purchaser and only if the
boiler has remained at all times in the location at which it was origi-
nally installed.
FIRST-YEAR LIMITED WARRANTY FOR RESIDENTIAL STEAM
BOILERS:
Slant/ in warrants its residential steam boilers to be free from
defects in material and workmanship for one year from date of orig-
inal installation. If any parts are found to be defective in material or
workmanship, Slant/ in will repair or replace the defective parts.
SECOND THROUGH TENTH YEAR LIMITED WARRANTY FOR
CAST-IRON SECTION ASSEMBLY OF RESIDENTIAL STEAM
BOILERS:
Slant/ in warrants the cast-iron section assembly of its residential
steam boilers to be free of defects in material and workmanship for
the second through the tenth year following the date of original
installation. If any sections are found to be defective during this peri-
od, Slant/ in will repair or replace the section or, at its option, the
entire heat exchanger.
See “Additional Warranty Terms” section for more details.
Limited Ten-Year Warranty
for Caravan Mod lar, Jag ar and
Commercial Application of Individ al
Cast-Iron Boilers in Hot Water and Steam
Heating Applications.
WARRANTY INCLUDES:
IRST YEAR: Repair or replacement in accordance with warranty
service procedure, for a period of one year after original installation,
of all parts found to be defectively manufactured.
SECOND THROUGH TENTH YEAR: Repair or replace for the sec-
ond through tenth year after original installation, of the cast iron or
cast aluminum heat exchanger found to be defectively manufac-
tured, at no cost for the replacement heat exchanger. Second
through tenth year warranty is for the heat exchanger only.
This warranty extends only to boilers installed in closed loop space
heating applications and domestic hot water applications. A proper-
ly sized heat exchanger must be used to heat the domestic water.
See “Additional Warranty Terms” section for more details.
2 thru 10 0% 18 40%
11 5% 19 45%
12 10% 20 50%
13 15% 21 55%
14 20% 22 60%
15 25% 23 65%
16 30% 24 70%
17 35% 25 & after 75%
Year of
Percentage paid by
consumer (of list price
at time of claim)
Percentage paid by
consumer (of list price
at time of claim)
Year of