Crown Boiler BWC151 User Manual
Table of Contents
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0
I. Product Description 2
II. Specifications 2
III. Before Installing 3
IV. Locating The Boiler 3
V. Mounting The Boiler 6
VI. Air For Ventilation 9
VII. Venting 11
A. Vent System Design 11
B. Removing An Existing Boiler From Common Chimney 21
C. Assembly of Crown 60/100mm Concentric Venting 22
D. Assembly of Crown 80/125mm Concentric Venting 26
E. Assembly of Stainless Steel Venting 35
F. Condensate Trap and Drain 40
VIII. Gas Piping 42
IX. System Piping 43
General System Piping Precaution 43
System Design 43
Standard Piping Installation Requirements 50
Piping For Special Situations 51
1
X. Wiring 53
XI. Start-up and Checkout 57
XII. Operation 63
XIII. Service and Maintenance 68
XIV. Troubleshooting 70
7
XV. Parts 73
Appendix A: Optional Method for Retrofitting BWC Boilers 85
into Existing Circulator Zone Systems
Appendix B: Special Requirements For Side-Wall 87
Vented Appliances In The Commonwealth
of Massachusetts
1
III Before Installing
1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict
accordance with this manual and the authority having jurisdiction.
• In the absence of an authority having jurisdiction, installation must be in accordance with this manual
and the National Fuel Gas Code, ANSI Z223.1. In Canada, installation must be in accordance with the
B149.1 Installation Code
• Where required by the authority having jurisdiction, this installation must conform to the Standard for
Controls and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1).
2) BWC boilers utilize aluminum heat exchangers constructed, tested, and stamped in accordance with ASME
Boiler and Pressure Vessel Code Case 2382. Some jurisdictions which require ASME boiler construction do
not recognize this Code Case and may not approve the installation of an aluminum boiler. Consult the authority having jurisdiction before installing this boiler.
3) Read Section VII to verify that the maximum combustion air and exhaust pipe lengths will not be exceeded in
the planned installation. Also verify that the vent terminal can be located in accordance with Section VII.
4) Make sure that the boiler is correctly sized:
• For heating systems employing convection radiation (baseboard or radiators), use an industry accepted
sizing method such as the I=B=R Heat Loss Calculation Guide (Pub. #H21 or #H22) published by the
Hydronics Institute in Berkely Heights, NJ.
• For new radiant heating systems, refer to the radiant tubing manufacturer’s boiler sizing guidelines.
• For systems including a Crown Mega-Stor indirect water heater, size the boiler to have either the DOE
Heating Capacity required for the Mega-Stor or the net rating required for the heating system, whichever
results in the larger boiler.
• For systems that incorporate other indirect water heaters, refer to the indirect water heater manufacturer’s
instructions for boiler output requirements.
5) Make sure that the boiler received is configured for the correct gas (natural or LP).
6) Make sure that the boiler is configured for use at the altitude at which it is to be installed.
NOTICE
This product must be installed by a licensed plumber or gas fitter when installed within the
Commonwealth of Massachusetts. See Appendix A for additional important information about
installing this product within the Commonwealth of Massachusetts.
IV Locating the Boiler
1) Observe the minimum clearances shown in Figure 4.1. These clearances apply to both combustible and noncombustible materials. Observe the minimum clearances to combustibles for vent pipe shown in Table 4.2.
2) Note the recommended service clearances in Figure 4.1. These service clearances are recommended, but may
be reduced to the combustible clearances provided:
a. Access to the front of the boiler is provided through a door.
b. Access is provided to the condensate trap and transformer located underneath the boiler.
3) When the boiler is installed on the floor using the optional pedestal kit, the boiler may be installed on a noncarpeted combustible surface.
4) The relief valve must be installed in the factory specified location.
3
Table 4.2: Clearances From Vent Piping To Combustible Construction
TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE
MINIMUM CLEARANCE
TO COMBUSTIBLE
MATERIAL
80/125 and 60/100mm
CONCENTRIC VENTING
HEAT FAB SAF-T VENT
PROTECH FASNSEAL
Z-FLEX Z-VENT III
METAL-FAB CORR/GUARD
HEAT FAB SAF-T VENT
PROTECH FASNSEAL
Z-FLEX Z-VENT III
METAL-FAB CORR/GUARD
HEAT FAB SAF-T VENT
PROTECH FASNSEAL
Z-FLEX Z-VENT III
METAL-FAB CORR/GUARD
VERTICAL OR
HORIZONTAL
VERTICAL OR
HORIZONTAL
HORIZONTAL OR VERTICAL
WITH OFFSETS
VERTICAL WITH NO OFFSETS ENCLOSED ON ALL FOUR SIDES
ENCLOSED ON ALL FOUR SIDES 0”
AT LEAST ONE SIDE OPEN,
COMBUSTIBLE MATERIAL ON A
MAXIMUM OF THREE SIDES
ENCLOSED ON ALL FOUR SIDES
1”
2-1/2”
2-1/2”
5
VI Air for Ventilation
WARNING
OUTDOOR COMBUSTION AIR MUST BE PIPED TO THE AIR INTAKE. NEVER PIPE COMBUSTION
AIR FROM AREAS CONTAINING CONTAMINATES SUCH AS SWIMMING POOLS AND LAUNDRY
ROOM EXHAUST VENTS. CONTAMINATED COMBUSTION AIR WILL DAMAGE THE BOILER
AND MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
Air for combustion must always be obtained directly from outdoors, however sufficient air for ventilation must
still be provided in the boiler room. Air for ventilation is required to keep various boiler components from overheating and is always obtained from indoors. To ensure an adequate ventilation air supply, perform the following
steps:
Step 1: Determine whether the boiler is to be installed in a confined space - A confined space is defined by the
National Fuel Gas Code as having a volume less than 50 cubic feet per 1000 BTU/hr input of all appliances
installed in that space. To determine whether the boiler room is a confined space:
1) Total the input of all appliances in the boiler room in thousands of BTU/hr. Round the result to the next
highest 1000 BTU/hr.
2) Find the volume of the room in cubic feet. The volume of the room in cubic feet is:
Length (ft) x width (ft) x ceiling height (ft)
In calculating the volume of the boiler room, consider the volume of adjoining spaces only if no doors are
installed between them. If doors are installed between the boiler room and an adjoining space, do not consider
the volume of the adjoining space, even if the door is normally left open.
3) Divide the volume of the boiler room by the input in thousands of BTU/hr. If the result is less than 50, the
boiler room is a confined space.
Example:
A BWC120 and a water heater are to be installed in a room measuring 6ft – 3 in x 7ft with an 8 ft ceiling. The
water heater has an input of 30000 BTU/hr:
Total input in thousands of BTU/hr = (120000 BTU/hr + 30000 BTU/hr) / 1000 = 150 MBTU/hr
Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft3
350/150 = 2.33. Since 2.33 is less than 50, the boiler room is a confined space.
Step 2a: If the boiler is to be placed in a confined space, provide two openings into the boiler room, one near the
floor and one near the ceiling. The top edge of the upper opening must be within 12” of the ceiling and the bottom
edge of the lower opening must be within 12” of the floor (Fig 6.1). The minimum opening dimension is 3 inches.
• If the BWC boiler is the only gas-burning appliance in the boiler room, these openings must each have a
minimum free area of 100 square inches.
• If other gas-burning appliances are in the boiler room, size the openings in accordance with the appliance
manufacturer’s instructions or the National Fuel Gas Code. Minimum opening free area is 100 square
inches even if opening requirements for other appliances are less.
9
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:
* Use only vent systems and materials explicitly permitted by Crown for use with this boiler.
* 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.
11
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.
• USA Only: 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. In
Canada, refer to B149.1 Installation Code for clearance to meters, regulators and relief 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.
12
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 7.2 7.3 7.2
VENT PIPE PENETRATION
THROUGH STRUCTURE
AIR INTAKE PIPE PENETRATION
THROUGH STRUCTURE
VENT PIPE SIZE
AIR INTAKE PIPE SIZE 3”
BWC070 32ft
BWC090 32ft
VENT
BWC120 18ft
BWC151
BWC070 32ft
BWC090 32ft
INLET
MAXIMUM LENGTH
MINIMUM LENGTH
VENT TERMINAL
AIR INTAKE TERMINAL 3” 90 ELBOW
BWC120 18ft
BWC151
BWC070 10in
BWC090 10in
VENT
BWC120 10in
BWC151
BWC070 10in
BWC090 10in
INLET
BWC120 10in
BWC151
HORIZONTAL
CONCENTRIC
WALL WALL WALL
WALL WALL WALL
60/100 mm
CONCENTRIC
60/100 mm
CONCENTRIC
HORIZONTAL
TWIN PIPE
3”
100ft 100ft
100ft 100ft
100ft 100ft
100ft 100ft
100ft 100ft
100ft 100ft
100ft 100ft
100ft 100ft
10in 10in
10in 10in
10in 10in
10in 10in
10in 10in
10in 10in
10in 10in
10in 10in
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
13
TABLE 7.4a: CROWN CONCENTRIC 60/100 VENT COMPONENTS
(VENT OPTION 1)
CROWN PN DESCRIPTION SIZE
230521
80/125 x 60/100mm REDUCING
ELBOW
80/125 x
60/100mm
USED ON
VENT
OPTION #
1
COMMENTS
INCLUDED WITH STANDARD
BWC070/090/120
230520 TERMINAL SECTION 60/100mm 1
230522 WALL GROMMET 60/100mm 1
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).
INCLUDED WITH STANDARD
BWC070/090/120
INCLUDED WITH STANDARD
BWC070/090/120
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
SUPPORT ELBOW WITH
CHIMNEY CHASE BRACKET
80/125mm 6 (NOTE #4)
VENT
OPTION #
COMMENTS
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.
15
46”.
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).
16
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
18
TABLE 7.8: VENT/ AIR INTAKE FITTING EQUIVALENT LENGTH
VENT FITTING EQUIVALENT LENGTH (ft)
60/100mm 90° CONCENTRIC ELBOW 4.5
60/100mm 45° CONCENTRIC ELBOW 4.0
80/125mm 90° CONCENTRIC ELBOW 8.5
80/125mm 90° SWEEP CONCENTRIC ELBOW 5.5
80/125mm 45° CONCENTRIC ELBOW 3.0
80/125mm 90° CONCENTRIC SUPPORT ELBOW 8.5
3” SINGLE WALL 90° ELBOW 5.5
3” SINGLE WALL 45° ELBOW 4.0
TABLE 7.9: SUMMARY OF VERTICAL VENTING OPTIONS
VENT OPTION # 5 6
CLASSIFICATION USED IN THIS
MANUAL
ILLUSTRATED IN FIGURE 7.10 7.11
VENT PIPE PENETRATION
THROUGH STRUCTURE
AIR INTAKE PIPE STRUCTURE
THROUGH STRUCTURE
VENT PIPE SIZE 3”
AIR INTAKE PIPE SIZE 3”
BWC070
BWC090
VENT
BWC120
BWC151
BWC070
BWC090
INLET
VENT
INLET
BWC120
BWC151
BWC070
BWC090
BWC120
BWC151
BWC070
BWC090
BWC120
BWC151
MAXIMUM LENGTH
MINIMUM LENGTH
VENT TERMINAL
AIR INTAKE TERMINAL
VERTICAL
TWIN PIPE
ROOF ROOF
ROOF ROOF
98ft 95ft
98ft 95ft
98ft 95ft
98ft 95ft
98ft 95ft
98ft 95ft
98ft 95ft
98ft 95ft
2ft 2ft
2ft 2ft
2ft 2ft
2ft 2ft
2ft 2ft
2ft 2ft
2ft 2ft
2ft 2ft
STRAIGHT TERMINAL
BY VENT SYSTEM MFR.
(TABLE 7.5)
3” 180° ELBOW
(FIGURE 7.10)
VERTICAL
CONCENTRIC
80/125 mm CONCENTRIC
CROWN #230532
CONCENTRIC TERMINAL
(TABLE 7.4b)
VENT MATERIAL
AIR INTAKE MATERIAL GALVANIZED OR PVC
APPROVED STAINLESS
STEEL VENT SYSTEM
19
CROWN 80/125 mm VENT
COMPONENTS SHOWN IN
TABLE 7.4b
FIGURE 7.10: VERTICAL TWIN PIPE VENT SYSTEM (VENT OPTION 5)
FIGURE 7.11: VERTICAL CONCENTRIC VENT SYSTEM (VENT OPTION 6)
20
B. Removing an Existing Boiler From a Common Chimney
Read this only if the BWC boiler is replacing an existing boiler that is being removed from a common chimney. This
section does not apply to the installation of a BWC boiler.
In some cases, when an existing boiler is removed from a common chimney, the common venting system may be too
large for the remaining appliances. At the time of removal of an existing boiler, the following steps shall be followed
with each appliance remaining connected to the common venting system placed in operation, while the other appliances
remaining connected to the common venting system are not in operation.
(a) Seal any unused openings in the common venting system.
(b) Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.
(c) Insofar as practical, close all building doors and windows and all doors between the space in which all the
appliances remaining connected to the common venting system are located and other spaces of the building.
Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a
summer exhaust fan. Close fireplace dampers.
(d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so the
appliance will operate continuously.
(e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a
match or candle, or smoke from a cigarette, cigar, or pipe.
(f) After it has been determined that each appliance remaining connected to the common venting system properly
vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other
gas-burning appliances to their previous condition of use.
(g) Any improper operation of the common venting system should be corrected so the installation conforms with
the National Fuel Gas Code, ANSI Z223.1. When re-sizing any portion of the common venting system, the
common venting system should be re sized to approach the minimum size as determined using the appropriate
tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1.
WARNING
NEVER COMMON VENT A BWC BOILER WITH OTHER APPLIANCES.
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C. Assembly of Crown 60/100mm Concentric Venting
(IMPORTANT - Skip to Section D for 80/125mm Concentric Vent Assembly)
WARNING
Failure to follow the instructions could result in flue gas leakage into the combustion air or indoor air,
resulting in unsafe or unreliable operation.
• Do not lubricate concentric gaskets with anything other than water.
• Do not attempt to cut any piping except as permitted in this section. When cutting these sections, make sure
all cuts are square and allow for proper insertion.
• Do not attempt to try to mix this concentric pipe with other venting systems.
1) Concentric vent components supplied with the boiler are packed inside the BWC070/090/120 carton and include
the following:
a) 80/125 x 60/100mm reducing elbow (Crown PN 230521).
b) 60/100mm terminal section (straight section with a terminal and overall length of 27 3/4” (Crown PN 230520).
c) Two (2) Rubber wall grommets (Crown PN 230522).
2) Unless the 80/125 straight riser (PN 230515) is used, start by attaching the reducing elbow to the boiler collar. To
do so, remove the clamp from the large end of the reducing elbow and set aside. Apply a small amount of water to
the brown gasket on the boiler collar. Push the elbow onto the boiler collar until the bead on the elbow contacts the
top edge of the collar (Figure 7.20).
3) Reinstall the clamp removed in Step (2) so that the elbow is secured to the boiler collar.
4) If no additional sections of concentric pipe are required, attach the terminal section to the elbow. In most cases, it
will need to be cut before doing so. Use the following procedure to cut the pipe:
a) Measure distance “L” from the outside surface of the exterior wall to the end of the elbow as shown in Figure
7.21.
b) Add 2-1/8” to distance “L”. Carefully mark this length on the pipe as shown in Figure 7.22.
c) Press in the two tabs holding the plastic terminal in the terminal section (Figure 7.22). Carefully pull out the
terminal and the inner pipe.
d) Cut the outer pipe only at the point marked in Step (b) using aviation shears, a hacksaw, or an abrasive wheel
cutter. Be careful to cut the pipe square. De burr the cut end with a file or emery cloth.
e) Cut the plastic inner pipe so that it will protrude 3/8” beyond the outer pipe when reinstalled in the terminal
section (Figure 7.23). Use a fine tooth hacksaw or a PVC saw to cut the plastic pipe and be careful to cut the pipe
square. De burr the cut edge of the plastic pipe with a file, razor blade, or fine sandpaper.
f) Reinstall the inner pipe in the terminal section. Slip the outside wall grommet over the terminal section and
position so that it covers the joint between the outer pipe and the terminal (Figure 7.24).
g) Make a mark on the terminal section 1” from the cut end of the outer pipe as shown in Figure 7.24.
h) Pass the terminal section through the wall from the outside. Push the remaining wall grommet over the terminal
section on the inside of the wall. Push the terminal section into the elbow until the mark made in Step (g) is no
longer visible. If necessary, the brown gasket in the inner pipe may be lubricated with a few drops of water.
i) The terminal section must be attached to the elbow with a single #10 x 1/2” sheet metal screw ( not supplied) at
the top of the elbow. Drill a 1/8” hole in the location shown in Figure 7.25. Use a short drill bit or a drill stop
to ensure that the drill bit does not penetrate the pipe by more than 3/8”. Install a #10 x 1/2” screw in this
hole. Do not use a screw longer than 1/2” long.
j) If not already done, make sure that both wall grommets are firmly against the interior and exterior wall surfaces.
Seal any cracks or other openings near the terminal through which exhaust could enter the building.
5) If additional pieces of pipe are used, install them starting at the boiler elbow. Support each section of straight pipe
at its female end.
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