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BWC090
User Manual
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Crown Boiler BWC070, BWC120, BWC090 User Manual

BWC070, BWC090, BWC120
Installation Manual Supplement
June 12
th
, 2007
1) 80/125mm concentric venting may be used to achieve longer vent runs.
2) 80/125mm concentric venting may be used for vertical vent applications.
3) An 80/125mm concentric snorkel kit is now offered.
4) Metal-Fab “Corr/Guard” may now be used for stainless steel vent applications.
Refer to the installation manual supplied with the boiler for important warnings and other information not covered in this supplement.
VII Venting
WARNING
FAILURE TO VENT THIS BOILER IN ACCORDANCE WITH THESE INSTRUCTIONS COULD CAUSE FLUE GAS TO ENTER THE BUILDING RESULTING IN SEVERE PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH:
* Do not attempt to vent this boiler with galvanized, PVC, or any other vent components not listed in Table 7.4.
* Do not attempt to mix components from different approved vent systems. * Do not obtain combustion air from within the building. * Do not install a barometric damper or drafthood on this boiler.
CAUTION
Moisture and ice may form on the surfaces around the vent termination. To prevent deterioration, surfaces should be in good repair (sealed, painted, etc.).
A. Vent System Design
There are four basic ways to vent this boiler:
• Horizontal (“Side Wall”) Concentric Venting - Vent system exits the building through an outside wall. Concentric venting consists of a “pipe within a pipe”. Flue gas exits the building through the inner pipe and combustion air is drawn into the boiler through the space between the inner and outer pipe.
• Horizontal (“Side Wall”) Twin Pipe Venting - Vent system exits the building through an outside wall. Combustion air and flue gas are routed between the boiler and outdoors using separate pipes.
• Vertical Concentric Venting - Vent system exits the building through the roof. Concentric venting consists of a “pipe within a pipe”. Flue gas exits the building through the inner pipe and combustion air is drawn into the boiler through the space between the inner and outer pipe.
• Vertical Twin Pipe Venting - Vent system exits the building through a roof. Combustion air and flue gas are routed between the boiler and outdoors using separate pipes.
All of these systems are considered “direct vent” because in all of them air for combustion is drawn directly from the outdoors into the boiler. A description of all of these venting options are shown in Tables 7.1 and 7.9. For clarity, these vent options are numbered from 1 to 6. One of the vent option columns in Tables 7.1 or 7.9 must match the planned vent and air intake system exactly. In addition, observe the following guidelines:
1) Approved vent systems - Use only one of the approved vent systems shown in Tables 7.4 or 7.5. These vent systems
fall into two basic categories:
• Concentric Vent System - The standard boiler is supplied with a concentric vent system having a maximum usable length of 25” (Figure 1.1). For longer runs, additional straight lengths and elbows are available from Crown. In some cases, larger diameter concentric pipe must be used. Each Crown concentric vent component consists of an inner pipe of polypropylene and the outer pipe of steel. Integral gaskets on each concentric fitting provide a gas tight seal. A list of all Crown concentric vent components is shown in Table 7.4.
In this manual, concentric pipe sizes are called out in terms of the inner and outer pipe nominal diameters in
millimeters. For example, “60/100mm” pipe consists of a 60mm exhaust pipe inside a 100mm diameter outer pipe.
• Twin Pipe Vent Systems - Approved vent systems are made of a special stainless steel alloy (AL29-4C) for protection against corrosive flue gas condensate. They are designed to provide a gas tight seal at all joints and seams so that flue gas does not enter the building. Each approved vent system has a unique method for installation
- do not attempt to mix components from different vent systems. A list of approved twin pipe vent systems is shown in Table 7.5. Note that a special vent collar (Crown PN 230510) is required if the boiler is to be vented with one of the approved stainless vent systems.
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2) Maximum Vent and Air Intake Lengths - The maximum length of the vent air intake piping depends upon the vent option selected and the boiler size. See Table 7.1 or 7.9 for the maximum vent length. In horizontal vent systems, the lengths shown in Table 7.1 are in addition to the first standard elbow on top of the boiler. For vertical vent systems, the maximum vertical vent lengths shown in Table 7.9 are in addition to two standard radius elbows. If more elbows are desired, the maximum allowable vent length must be reduced by the amount shown in Table 7.8 for each additional elbow used. Termination fittings are never counted, although the length of the concentric terminal section is counted.
Example:
A 60/100mm concentric vent system is planned for a horizontally vented BWC120 which has the following
components:
80/125 x 60/100mm Reducing Elbow (supplied with the boiler) 5ft Straight Pipe 90 elbow 1-1/2ft Straight Pipe 45Elbow Uncut Terminal Section (supplied with the boiler)
The Vent Option #1 column in Table 7.1 describes a horizontal direct vent system using 60/100mm concentric vent
pipe. From this column, we see that a BWC120 may have a vent length of up to 18ft. The 90 degree reducing elbow is not considered. The length of the terminal section (not including the plastic terminal itself) is approximately 22 1/2” (1.9ft) installed. From Table 7.8, we see that the equivalent length of the 60/100mm elbow is 4.5ft and that the equivalent length of the 45 degree elbow is 4ft. The total equivalent length of the planned venting system is therefore:
5ft (Straight ) + 4.5ft (90 Elbow) + 1.5ft (Straight ) + 4 ft (45 Elbow) + 1.9ft (Uncut Terminal Section) = 16.9ft.
Since Table 7.1 shows a maximum allowable vent length of 18ft, the planned vent system length is acceptable.
3) Minimum Vent and Air Intake Lengths - Observe the minimum vent lengths shown in tables 7.1 and 7.9.
4) Permitted Terminals for Horizontal Venting:
• Vent Option 1 - The 60/100mm concentric vent terminal is supplied with the boiler as part of the standard vent system.
• Vent Option 2 - The exhaust terminal is Crown PN 230511. The air intake fitting is a 90 degree elbow with a rodent screen supplied by the installer. This elbow is made out of the same material as the rest of the air inlet system (either galvanized or PVC) and is installed as shown in Figure 7.3.
• Vent Option 3 - Two terminals are permitted:
a) 80/125mm Concentric Vent Terminal (Crown PN 230531) b) 80/125mm Snorkel Terminal (Crown PN 230540) . This terminal allows the vent system to exit the building
close to grade and go up the exterior wall far enough to provide adequate clearance between the terminal itself and the snow line (Figure 7.7).
5) Horizontal Vent and Air Intake Terminal Location - Observe the following limitations on the vent terminal location (also see Figures 7.6, 7.7). When locating a concentric terminal, observe the limitations outlined below for “vent terminals”.
• Vent terminals must be at least 1 foot from any door, window, or gravity inlet into the building.
• For twin pipe terminals, maintain the correct clearance and orientation between the vent and air intake terminals. The vent and air intake terminals must be at the same height and their center lines must be between 12 and 36 inches apart. Both terminals must be located on the same wall.
• The bottom of all terminals must be at least 12” above the normal snow line. In no case should they be less than 12” above grade level.
• The bottom of the vent terminal must be at least 7 feet above a public walkway.
• Do not install the vent terminal directly over windows or doors.
• The bottom of the vent terminal must be at least 3 feet above any forced air inlet located within 10 feet.
• A clearance of at least 4 feet horizontally must be maintained between the vent terminal and gas meters, electric meters, regulators, and relief equipment. Do not install vent terminal over this equipment.
• Do not locate the vent terminal under decks or similar structures.
• Top of vent terminal must be at least 5 feet below eves, soffits, or overhangs. Maximum depth of overhang is 3 ft.
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Horizontal Terminal Clearance Requirements (continued):
• Vent terminal must be at least 6 feet from an inside corner.
• Under certain conditions, water in the flue gas may condense, and possibly freeze, on objects around the vent terminal including on the structure itself. If these objects are subject to damage by flue gas condensate, they should be moved or protected.
• If possible, install the vent and air intake terminals on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if these terminals are subjected to winds in excess of 40 mph.
• Air intake terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming pools. See Section IV for more information on possible contaminates.
TABLE 7.1: SUMMARY OF HORIZONTAL VENTING OPTIONS
VENT OPTION # 1 2 3
CLASSIFICATION USED IN THIS MANUAL
ILLUSTRATED IN FIGURE
VENT PIPE PENETRATION THROUGH STRUCTURE
AIR INTAKE PIPE PENETRATION THROUGH STRUCTURE
VENT PIPE SIZE
AIR INTAKE PIPE SIZE
BWC070 32ft
BWC090 32ft
VENT
BWC120 18ft
BWC070 32ft
BWC090 32ft
INLET
MAXIMUM LENGTH
MINIMUM LENGTH
VENT TERMINAL
AIR INTAKE TERMINAL 3” 90 ELBOW
BWC120 18ft
BWC070 10in
BWC090 10in
VENT
BWC120 10in
BWC070 10in
BWC090 10in
INLET
BWC120 10in
HORIZONTAL CONCENTRIC
7.2 7.3 7.2
WALL WALL WALL
WALL WALL WALL
60/100 mm
CONCENTRIC
60/100 mm
CONCENTRIC
HORIZONTAL
TWIN PIPE
3”
3”
55ft 55ft
55ft 55ft
55ft 55ft
55ft 55ft
55ft 55ft
55ft 55ft
2ft 2ft
2ft 2ft
2ft 2ft
2ft 2ft
2ft 2ft
2ft 2ft
CROWN
#230511
HORIZONTAL CONCENTRIC
80/125 mm
CONCENTRIC
Crown 230531
CONCENTRIC
or 230540
SNORKEL
CROWN
VENT MATERIAL
AIR INTAKE MATERIAL
Note #1: In Vent Option #1, the 80/125mm concentric straight section (PN 230515) shown in Table 7.4a may be used between the boiler and the first 80/125 x 60/100 reducing elbow. If this is done, the overall maximum vent length is still restricted to that shown for Vent Option #1 in Table 7.1 above.
60/100mm
VENT
COMPONENTS
SHOWN IN
TABLE 7.4a
(Note #1)
APPROVED STAINLESS
STEEL VENT
SYSTEM
SHOWN IN
TABLE 7.5
GALVANIZED
OR PVC
CROWN
80/125mm VENT
COMPONENTS
SHOWN IN
TABLE 7.4b
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FIGURE 7.2: HORIZONTAL CONCENTRIC VENTING (VENT OPTION 1,3)
FIGURE 7.3: HORIZONTAL TWIN PIPE VENTING (VENT OPTION 2)
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TABLE 7.4a: CROWN CONCENTRIC 60/100 VENT COMPONENTS
(VENT OPTION 1)
USED ON
CROWN PN DESCRIPTION SIZE
230521
230520 TERMINAL SECTION 60/100mm 1 INCLUDED WITH STANDARD BOILER
230522 WALL GROMMET 60/100mm 1 INCLUDED WITH STANDARD BOILER
230505 39” STRAIGHT 60/100mm 1 OPTIONAL - MAY NOT BE CUT
230504 78” STRAIGHT 60/100mm 1 OPTIONAL - MAY NOT BE CUT
230506 19 1/2” STRAIGHT 60/100mm 1 OPTIONAL - CAN BE CUT
230507 90 DEGREE ELBOW 60/100mm 1 OPTIONAL
230508 45 DEGREE ELBOW 60/100mm 1 OPTIONAL
230515 39” STRAIGHT 80/125mm 1 OPTIONAL - CAN BE CUT (Note #1)
Note #1: On 60/100mm vent systems, this may only be used between the boiler and the first 80/125 x 60/100 Reducing elbow (see text).
80/125 x 60/100mm REDUCING
ELBOW
80/125 x 60/100mm
VENT
OPTION #
1 INCLUDED WITH STANDARD BOILER
COMMENTS
TABLE 7.4b: CROWN CONCENTRIC 80/125 VENT COMPONENTS
(VENT OPTIONS 3,6)
USED ON
CROWN PN DESCRIPTION SIZE
230527 90 DEGREE EL (STANDARD) 80/125mm 3,6
230528 90 DEGREE EL (SWEEP) 80/125mm 3,6
230526 45 DEGREE EL 80/125mm 3,6
230517 19 1/2” STRAIGHT 80/125mm 3,6 CAN BE CUT
230515 39” STRAIGHT 80/125mm 3,6 CAN BE CUT
230518 39” STRAIGHT 80/125mm 3,6 MAY NOT BE CUT
230519 78” STRAIGHT 80/125mm 3,6 MAY NOT BE CUT
230525 TELESCOPING STRAIGHT 80/125mm 3,6 ADJUSTABLE FROM 12-1/2” TO 16-1/2
230531 HORIZONTAL TERMINAL 80/125mm 3
230540 SNORKEL KIT 80/125mm 3 (NOTE #1)
230532 VERTICAL TERMINAL 80/125mm 6 (NOTE #2)
230533 FLAT ROOF FLASHING 80/125mm 6
230535 SLOPED ROOF FLASHING 80/125mm 6 (NOTE #3)
230530
230536 SUPPORT BAND 80/125mm 3,6
Table 7.4b Notes:
1) Snorkel kit includes parts needed to offset terminal on exterior wall by up to
2) Vertical terminal can be used with either of the roof flashings listed beneath it.
3) Sloped roof flashing suitable for roof angles between 25 and 45 degrees.
4) Used at base of vertical run inside unused masonry chimney.
SUPPORT ELBOW WITH
CHIMNEY CHASE BRACKET
80/125mm 6 (NOTE #4)
VENT
OPTION #
46”.
COMMENTS
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6) Permitted Terminals for Vertical Venting -
• Vent Option 5 - A straight termination is installed in the end of the vent pipe. Vent manufacturer part numbers for these screens are shown in Table 7.5. The air inlet terminal consists of a 180 degree elbow (or two 90 degree elbows) with a rodent screen as shown in Figure 7.10.
• Vent Option 6 - Use Crown PN 230532 with the appropriate flashing (Table 7.4b)
7) Vertical Vent Terminal Locations (Vent Options 5,6) - Observe the following limitations on the location of all vertical vent terminals (see Figures 7.10, 7.11):
• The top of the vent pipe must be at least 2 feet above any object located within 10 feet.
• For Vent Option #5, the vertical distance between top of the vent and air inlet terminal openings must be at least 12”.
• The bottom of the air inlet terminal must be at least 12” above the normal snow accumulation that can be expected on the roof. The terminal used in Vent Option #6 has a fixed distance above the storm collar of 19”. If a greater distance is needed to provide the clearance above the snow line, build a chase on the roof and mount the vertical terminal on top of the chase.
• For Vent Option #5, the air intake terminal must be located on the roof and must be no further than 24” horizontally from the exhaust pipe.
8) Wall thimbles – Wall thimbles are required where single wall vent pipe passes through combustible walls with less than the required clearance shown in Table 4.2 or as required by local codes. Stainless vent manufacturer’s wall thimble part numbers are shown in Table 7.5. Note that concentric vent has a “zero” clearance to combustibles and therefore does not require the use of wall thimbles.
MANUFACTURER
HEAT FAB
PROTECH SYSTEMS
INC.
Z-FLEX
METAL-FAB
TABLE 7.5: PERMISSIBLE STAINLESS STEEL VENT SYSTEMS
AND PRINCIPLE VENT COMPONENTS
(VENT OPTIONS 2, 5)
VENT
SYSTEM
SAF-T VENT
EZ SEAL
FASNSEAL
SVE
SERIES III
(“Z-VENT
III”)
CORR/
GUARD
SIZE COMPONENT PART NUMBER
3 BOILER COLLAR CROWN 230510
3 WALL THIMBLE HEAT FAB 7393, 7393GCS, 5391CI
3 HORIZONTAL TERMINAL CROWN 230511
3 VERTICAL TERMINAL HEAT FAB 9392
3 BOILER COLLAR CROWN 230510
3 WALL THIMBLE FSWT3
3 HORIZONTAL TERMINAL CROWN 230511
3 VERTICAL TERMINAL FSBS3
3 BOILER COLLAR CROWN 230510
3 WALL THIMBLE 2SVSWTEF03
3 HORIZONTAL TERMINAL CROWN 230511
3 VERTICAL TERMINAL 24SVSTPF03
3 BOILER COLLAR CROWN 230510
3 WALL THIMBLE CGSWWPK(3”)
3 HORIZONTAL TERMINAL CROWN 230511
3 VERTICAL TERMINAL CGSWHTM(3”)
NOTES:
1) See vent system manufacturer’s literature for other part numbers that are required such as straight pipe, elbows, firestops and vent supports.
2) Crown 230510 collar replaces factory-mounted concentric collar (Figure 7.16).
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FIGURE 7.6a: LOCATION OF VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE
FIGURE 7.6b: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS
FIGURE 7.6c: POSITIONING VENT TERMINAL UNDER OVERHANGS
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9) Pitch of Horizontal Piping - Pitch all horizontal piping so that any condensate which forms in the piping will run towards the boiler:
• Pitch Crown horizontal concentric venting 5/8” per foot
• Pitch Stainless steel venting 1/4” per foot.
10) Supporting Pipe - Vertical and horizontal sections of pipe must be properly supported:
• Support Crown concentric venting near the female end of each straight section of pipe.
Exception: Vertical runs of concentric pipe in an unused chinmey (Figure 7.36) need only be supported at the
terminal and at the base of the run.
• Support stainless steel venting as called for by the vent manufacturer’s instructions.
FIGURE 7.7: SNORKEL TERMINAL CONFIGURATION
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