Crown Boiler BWC225, BWC150 User Manual

BWC Series

D ESIGNED TO L EAD

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

Tel: [phone] • Fax: [phone] • www.crownboiler.com

Direct Vent Condensing Boilers

INSTALLATION SUPPLEMENT FOR BOILERS
VENTED WITH CPVC/PVC PIPE

These instructions must be afxed on or adjacent to the boiler.

Models:

• BWC070

• BWC090

• BWC120

• BWC151

• BWC150

• BWC225

WARNING: Improper installation, adjustment, alteration,
service or maintenance can cause property damage, injury,
or loss of life. For assistance or additional information, con-

sult a qualied installer, service agency or the gas supplier.
This boiler requires a special venting system. Read these
instructions carefully before installing.

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Table of Contents

A. Vent System Design 2
B. Assembly of CPVC/PVC Concentric Venting 14
C. Condensate Trap and Drain 20
D. Removing An Existing Boiler From Common Chimney 22
E. Special Requirements For Side-Wall Vented Appliances
In The Commonwealth of Massachusetts 23

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WARNING

Failure to vent this boiler in accordance with these instructions could cause ue gas to enter the building
resulting in severe property damage, personal injury, or death:

Use of the BWC boiler with CPVC/PVC venting requires a special vent kit available from Crown •
Boiler Company. Do not attempt to vent the boiler using either CPVC/PVC without the use of the
appropriate vent kit called for in this manual.
Do not apply thermal insulation to vent pipe or ttings.•
Do not interchange vent systems or materials unless otherwise specied.•
Do not obtain combustion air from within the building. •
Do not install a barometric damper, vent damper, or drafthood on this boiler.•
Unless otherwise noted, the• use of CPVC is required where the vent pipe passes through enclosed
spaces and through wall penetrations.
Do not use cellular core PVC (ASTM F891).•
Pitch the vent piping as called for in these instructions to prevent condensate from pooling in the •
venting.
Starting at the boiler, the rst 30” of straight pipe, and the rst 90 degree elbow, in the vent system •
must be CPVC. PVC may only be used in the vent system downstream of this CPVC piping.

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 several different ways to vent BWC series boilers. This installation supplement covers installation of
those vent systems that employ CPVC and PVC plastic pipe. Refer to the BWC installation manual when installing a
vent system using stainless steel or concentric PPs venting.

When CPVC/PVC pipe is used, there are two basic ways to vent a BWC boiler, each having several variations:

• Horizontal (“Side Wall”) Twin Pipe Venting (Table 1.1) - Vent system exits the building through an outside

wall. Combustion air and ue gas are routed between the boiler and the terminal using separate pipes.

• Vertical Twin Pipe Venting (Table 1.12) - Vent system exits the building through a roof. Combustion air and

ue gas are routed between the boiler and the terminal 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 1.1 and 1.12. One of
the vent option columns in Tables 1.1 or 1.12 must match the planned vent and air intake system exactly. In addition,
observe the following guidelines:

CPVC/PVC Adaptor Kits1. - The use of CPVC/PVC venting on BWC boilers requires the use of a special kit. Each

kit consists of the following principle components:

Adaptor/s for the Vent and Intake Connections•
30” Section of Straight CPVC Pipe•
CPVC Elbow•
(2) PVC Termination Tees•
(2) Rodent Screens•
(1 ea.) Can PVC/CPVC Primer and Cement•

Part Numbers for each kit are shown in Table 1.5

NOTE: Models BWC070, 090, 120 and 151 may be ordered from the factory with the above components
packaged in the boiler. When this is done the vent adaptor may be shipped installed on the boiler.

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TABLE 1.1: SUMMARY OF HORIZONTAL VENTING OPTIONS

VENT OPTION # 1 2 3 4

CLASSIFICATION USED IN THIS
MANUAL

ILLUSTRATED IN FIGURE 1.2 1.3 1.4 1.4

VENT PIPE PENETRATION
THROUGH STRUCTURE

AIR INTAKE PIPE PENETRATION
THROUGH STRUCTURE

VENT PIPE SIZE

AIR INTAKE PIPE SIZE

BWC070 100ft 100ft

BWC090 100ft 100ft

BWC120 100ft 100ft

VENT

BWC151 100ft 100ft

BWC150

BWC225

BWC070 100ft 100ft

BWC090 100ft 100ft

MAXIMUM LENGTH

MINIMUM LENGTH

BWC120 100ft 100ft

BWC151 100ft 100ft

INLET

BWC150

BWC225

BWC070 2ft 2ft

BWC090 2ft 2ft

BWC120 2ft 2ft

VENT

BWC151 2ft 2ft

BWC150

BWC225

BWC070 2ft 2ft

BWC090 2ft 2ft

BWC120 2ft 2ft

INLET

BWC151 2ft 2ft

BWC150 2ft

BWC225 2ft

HORIZONTAL

TWIN PIPE

WALL WALL WALL WALL

WALL WALL WALL WALL

3” 3”

3” 3”

HORIZONTAL

TWIN PIPE

HORIZONTAL

TWIN PIPE

3” 4”

4” 4”

55ft

60ft

2ft

HORIZONTAL

TWIN PIPE

55ft

60ft

2ft

VENT TERMINAL TEE (Note #1)

AIR INTAKE TERMINAL TEE (Note #1) TEE (Note #1) TEE (Note #1)

VENT MATERIAL

AIR INTAKE MATERIAL PVC PVC PVC PVC

Note #1: TEEs may be offset on snorkels as shown in Figure 1.10
Note #2: First 30” and Elbow connected to boiler must be CPVC. Downstream vent pipe can be PVC, except as noted in text.

CPVC + PVC

(Note #2)

CROWN

PN 230873

CONCENTRIC

TERMINAL

CPVC + PVC

(Note #2)

TEE (Note #1) TEE (Note #1)

CPVC + PVC

(Note #2)

CPVC + PVC

(Note #2)

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Approved vent components and materials - The adaptor kits listed in Table 1.5 are required to connect the venting 2.
to the boiler. Starting at the boiler, the rst 30 inches of the vent system, and the rst elbow, must be CPVC. In
addition, use only pipe that meets the following standards:

CPVC - ASTM F441•
PVC - ASTM D2665•

The primer and cement used must be designed for use with the venting materials being joined (PVC, CPVC or
CPVC to PVC).

CAUTION

The CPVC and PVC vent materials supplied with this boiler do not comply with B149.1.S1-07 and are not
approved for use in Canadian jurisdictions that require that vent systems be listed to ULC S636-2008. In
these jurisdictions, vent this boiler using one of the AL29-4c stainless steel vent systems shown in the BWC
installation manual or a listed ULC S636 Class II - 90°C venting system.

Maximum Vent and Air Intake Lengths3. - The maximum length of the vent air intake piping depends upon the
vent option selected and the boiler size. See Table 1.1 or 1.12 for the maximum vent lengths. In horizontal

vent systems, the lengths shown in Table 1.1 are in addition to the rst 90 elbow. For vertical vent systems, the

maximum vertical vent lengths shown in Table 1.12 are in addition to two 90 elbows. If more elbows are desired, the
maximum allowable vent length must be reduced by the amount shown in Table 1.7 for each additional elbow used.

Termination ttings are never counted.
The elbows supplied in the CPVC/PVC vent kit are “standard radius” elbows. It is recommeded that all eld

supplied elbows must be “1/4 Bend” (Sanitary 90 El) or “Long Sweep 1/4 Bend” type elbows (Figure 1.8). In this
manual “sanitary” and “long sweep” elbows are treated as having the same equivalent length.

Example:

A 3” twin pipe horizontal CPVC/PVC vent system is planned for a horizontally vented BWC120 which has the
following components in the vent system:

1 ft CPVC Straight Pipe•
90 CPVC Elbow (Supplied in Crown vent kit)•
1-1/2 ft CPVC Straight Pipe•
Coupling•
10 ft PVC Straight Pipe•
90 PVC Elbow (Sanitary Elbow Design)•
15 ft PVC Straight Pipe•
PVC Tee Terminal•

The Vent Option #1 column in Table 1.1 describes a horizontal direct vent system using 3” CPVC and PVC pipe.

Fromthiscolumn,weseethataBWC120mayhaveaventlengthofupto100ft.TherstCPVC90degreeelbowis

not considered. From Table 1.7, we see that the equivalent length of the 90 PVC elbow is 4ft and that the equivalent
length of the coupling is 0ft. The total equivalent length of the planned venting system is therefore:

1ft(StraightCPVC)+0ft(rstCPVC90Elbow)+1.5ft(StraightCPVC)+0ft(Coupling)+10ft (Straight PVC) +

4ft (PVC 90 Elbow) + 15ft (Straight PVC) + 0ft (Tee Terminal) = 31.5ft.

Since Table 1.1 shows a maximum allowable vent length of 100ft, the planned vent system length is acceptable.

Minimum Vent and Air Intake Lengths 4. - Observe the minimum vent lengths shown in Table 1.1.

Permitted Terminals for Horizontal Venting (Vent Option #1-3)5. - Use one of the following terminals:

PVC Teesa. - PVC Tees are used for both the inlet and vent. They are the same size as the connected vent
or intake system and are installed with the run vertical as shown in Figures 1.2 and 1.4. Rodent screens are
installed in the side connection of the Tee where it is connected to the vent or intake pipe. Terminal Tees and
rodent screens are provided with the CPVC/PVC vent kit.
PVC Tees on Snorkelsb. - If desired, the PVC Tees terminations may be installed on snorkels as shown in Figure

1.10. When this is done, all exterior piping except for the termination Tees themselves must be counted when
calculating the equivalent length. The maximum vertical run of the snorkel is 5ft. Observe all restrictions on the
location of the Tee terminal described in Paragraph 6.
Crown Concentric Terminc. al (PN 230873 ) - This optional terminal may be used in place of the Tees on the
BWC070, 090, 120, and 151 (Figure 1.3). It may not be used on the BWC150 or 225.

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FIGURE 1.2: HORIZONTAL CPVC/PVC VENTING, BWC070/090/120/151 (Vent Option #1)

FIGURE 1.3: HORIZONTAL CPVC/PVC VENTING, BWC070/090/120/151 (Vent Option #2)

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Horizontal Vent and Air Intake Terminal Location6. - Observe the following limitations on the vent terminal location
(also see Figure 1.9). 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.•
For Tee terminals, maintain the correct clearance and orientation between the vent and air intake terminal. •
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, sof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 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 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.
Air intake terminal must not terminate in areas that might contain combustion air contaminates, such as near •
swimming pools. See the installation manual for more information on possible contaminates.

Permitted Terminals for Vertical Venting7. - Use either of the following terminals:

Coupling On Vent, 180 Bend On Inleta. - A coupling is installed in the end of the vent pipe. Install a rodent
screen between this coupling and the last piece of vent piping. Use a 180 bend or two 90 elbows to make the
inlet termination (Figures 1.14, 1.16). Rodent screens are provided with the CPVC/PVC vent kit. The elbow/s
and coupling must be procured locally.
Crown Concentric Terminal (PN b. 230873) - This optional terminal may be used in place of the coupling and
180 bend on the BWC070, 090, 120, and 151 (Figure 1.15). It may not be used on the BWC150 or BWC225.

Vertical Vent Terminal Locations (Vent Options 5,6)8. - Observe the following limitations on the location of all
vertical vent terminals (see Figures 1.14 - 1.16):

The top of the vent pipe must be at least 2 feet above any object located within 10 feet.•
For Coupling/Elbow terminations, 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.
For Coupling/Elbow terminations, the air intake terminal must be located on the roof and must be no further •
than 24” horizontally from the exhaust pipe.

Clearances to Combustibles9. - Maintain the following clearances from the vent system to combustible construction:

Vent - 1” (also observe clearances through both combustible and non-combustible walls - see 10 below)•
Air Intake - 0”•
Concentric Portion of • Crown 230873 Terminal - 0”

Running PVC Vent Pipe Inside Enclosures and Through Walls10. - PVC vent pipe must be installed in a manner that
permits adequate air circulation around the outside of the pipe:

Do not enclose PVC venting - Use CPVC in enclosed spaces, even if PVC is installed upstream. •
PVC venting may not be used to penetrate combustible or non-combustible walls unless all of the following •
conditions are met:

The wall pentration is at least 66 inches from the boiler as measured along the vent.a.
The wall is 12” thick or lessb.
An airspace of at least that shown in Figure 1.13 is maintained around the OD of the vent.c.

If any of these conditions cannot be met, use CPVC for the wall pentetration.

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