Crown Boiler BWC150, BWC225 User Manual
D E S I G N E D T O L E A D
BWC Series
BWC150/225 CONCENTRIC VENTING
INSTALLATION INSTRUCTIONS
These instructions must be affi xed on or adjacent to the boiler.
Models:
• BWC150
• BWC225
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com
WARNING: Improper installation, adjustment, alteration,
service or maintenance can cause property damage, injury ,
or loss of life. For assistance or additional information, consult a qualifi ed installer, service agency or the gas supplier.
This boiler requires a special venting system. Read these
instructions carefully before installing.
Table of Contents
A. Concentric Vent System Design 2
B. Concentric Vent Adapter Kit Installation 9
C. Assembly of Crown Concentric Venting and Condensate Drain 11
1
WARNING
F AILURE T O 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 1.6.
* 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.).
Concentric Venting For BWC150 and BWC225
A. Concentric Vent System Design
In addition to the vent options listed in the installation manual there are two other 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.
• 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.
These systems are considered “direct vent” because air for combustion is drawn directly from the outdoors into
the boiler. A description of these venting options are shown in Tables 1.1 and 1.5. For clarity, the vent options
are numbered 3 and 4 for the horizontal options and 8 and 9 for the vertical options. One of the vent option columns
in Tables 1.1 or 1.5 must match the planned vent and air intake system exactly. In addition, observe the following
guidelines:
1) Approved concentric vent systems - The concentric vent system is optional for the BWC150 and BWC225 boilers.
Each Crown concentric vent component consists of an inner pipe of polypropylene and the outer pipe of steel.
Integral gaskets on each concentric fi tting provide a gas tight seal. Concentric pipe sizes are called out in terms
of the inner and outer pipe nominal diameters in millimeters. For example, “80/125mm” pipe consists of a 80mm
exhaust pipe inside a 125mm diameter outer pipe. A list of all Crown concentric vent components is shown in Table
1.6. Use only one of the approved concentric vent systems shown in Table 1.6.
A concentric vent adapter kit is required to use these boilers with concentric pipe. Part numbers for these kits are:
BWC150 P/N 230550
BWC225 P/N 230555
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 1.1 or 1.5 for the maximum vent length. In horizontal vent systems,
the lengths shown in Table 1.1 are in addition to the vent components which come with the Air Intake Box Kit and
one standard radius elbow. For vertical vent systems, the maximum vertical vent lengths shown in Table 1.5 are in
addition to the vent components which come with the Air Intake Box Kit and two standard radius elbows. If more
elbows are desired, the maximum allowable vent length must be reduced by the amount shown in Table 1.4 for each
additional elbow used. Termination fi ttings are never counted, although the length of the concentric terminal section
is counted.
2
Example:
A 80/125mm concentric vent system is planned for a horizontally vented BWC150 which has the following
components:
Standard Radius 90° Elbow
5ft Straight Pipe
Standard Radius 90° Elbow
1-1/2ft Straight Pipe
45° Elbow
Uncut Terminal Section
The Vent Option #3 column in Table 1.1 describes a horizontal direct vent system using 80/125mm concentric vent
pipe. From this column, we see that a BWC150 may have a vent length of up to 55ft The fi rst 90° standard radius
elbow is not considered. The length of the terminal section (not including the terminal itself) is approximately 22.1”
(1.84ft) installed. From Table 1.4, we see that the equivalent length of the 80/125mm 90° elbow is 8.5ft and that
the equivalent length of the 45 degree elbow is 3.0ft. The total equivalent length of the planned venting system is
therefore:
5ft (Straight ) + 8.5ft (90 Elbow) + 1.5ft (Straight ) + 3.0ft (45 Elbow) + 1.84ft (Uncut Terminal Section) = 19.84ft.
Since Table 1.1 shows a maximum allowable vent length of 55ft, the planned vent system length is acceptable.
3) Minimum Vent and Air Intake Lengths - Observe the minimum vent lengths shown in Tables 1.1 and 1.5.
4) Permitted Terminals for Horizontal Venting:
• Vent Option 3 - 80/125mm Concentric Vent Terminal (Crown PN 230531)
• Vent Option 4 - 100/150mm Concentric Vent Terminal (Crown PN 230569)
5) Horizontal Vent and Air Intake Terminal Location - Observe the following limitations on the vent terminal location
(also see Figure 1.3). When locating a concentric terminal, observe the limitations outlined below for “vent
terminals”.
• Vent terminal must be at least 1 foot from any door, window, or gravity inlet into the building.
• The bottom of terminal must be at least 12” above the normal snow line. In no case should it 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, soffi ts, or overhangs. Maximum depth of overhang is 3 ft.
• Vent terminal must be at least 6 feet from an inside corner.
• Under certain conditions, water in the fl ue 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 fl ue 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.
• Terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming
pools. See Section IV in the installation manual for more information on possible contaminates.
3
TABLE 1.1: SUMMARY OF HORIZONTAL VENTING OPTIONS
VENT OPTION # 3 4
CLASSIFICATION USED IN THIS
MANUAL
ILLUSTRATED IN FIGURE 1.2 1.2
VENT PIPE PENETRATION
THROUGH STRUCTURE
AIR INTAKE PIPE PENETRATION
THROUGH STRUCTURE
VENT PIPE SIZE
AIR INTAKE PIPE SIZE
BWC150 55
VENT
BWC225 55
BWC150 55
INLET
MAXIMUM LENGTH
MINIMUM LENGTH
BWC225 55
BWC150 2
VENT
BWC225 2
BWC150 2
INLET
BWC225 2
HORIZONTAL
CONCENTRIC
WALL WALL
WALL WALL
80/125 mm
CONCENTRIC
CONCENTRIC
HORIZONTAL
CONCENTRIC
100/150 mm
VENT TERMINAL
AIR INTAKE TERMINAL
VENT MATERIAL
AIR INTAKE MATERIAL
Crown 230531
CONCENTRIC
TERMINAL
CROWN
80/125mm
COMPONENTS
SHOWN IN
TABLE 1.6a
4
VENT
Crown 230569
CONCENTRIC
TERMINAL
CROWN
100/150mm
VENT
COMPONENTS
SHOWN IN
TABLE 1.6b
FIGURE 1.2: HORIZONTAL CONCENTRIC VENTING
(VENT OPTION 3,4)
6) Permitted Terminals for Vertical Venting -
• Vent Option 8 - Use Crown PN 230532 with the appropriate fl ashing (Table 1.6a)
• Vent Option 9 - Use Crown PN 230570 with the appropriate fl ashing (Table 1.6b)
7) Vertical Vent Terminal Locations (Vent Options 8,9) - Observe the following limitations on the location of all vertical vent
terminals (see Figure 1.7):
• The top of the vent pipe must be at least 2 feet above any object located within 10 feet.
• 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 Options 8 & 9 has a fi xed 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.
8) Wall thimbles – Concentric vent has a “zero” clearance to combustibles and therefore does not require the use of wall
thimbles.
9) Pitch of Horizontal Piping - Pitch all horizontal piping 5/8” per foot so that any condensate which forms in the piping will
run towards the boiler:
10) Supporting Pipe - Support Crown concentric venting near the female end of each straight section of pipe.
Exception: Vertical runs of concentric pipe in an unused chimney (Figure 1.14) need only be supported at the
terminal and at the base of the run.
5
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