Crown Boiler CWD220, CWD083, CWD110, CWD193, CWD245 User Manual

...

CWD Series

Gas-Fired Direct Vent Hot Water Boilers INSTALLATION INSTRUCTIONS

These instructions must be afﬁ xed on or adjacent to the boiler

Models:

• CWD060

• CWD083

• CWD110

• CWD138

• CWD165

• CWD193

• CWD220

• CWD245

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. Read these instructions carefully before installing.

TABLE OF CONTENTS

I Product Description 1

II Speciﬁ cations 1 III Before Installing 2 IV Locating the Boiler 2

V Air for Combustion and Ventilation 4 VI Venting 9

Vent System Design 9 Vent System Assembly 22

VII Gas Piping 32

VIII System Piping 33

IX Wiring 38

CB502 Control System 38 R8285 Control system 44

X Start-up and Checkout 48 XI Service and Maintenance 52

XII Troubleshooting 57

XIII Parts 65

Appendix A:Special Requirements for Side-Wall Vented Appliances in the Commonwealth of Massachusetts

I Product Description

The CWD series boiler is a cast iron gas ﬁ red boiler designed for use in forced hot water heating systems. It is is a low pressure boiler intended for use in closed heating systems with water temperatures under 240F. This boiler may be vented either vertically or horizontally with combustion air supplied from either outdoors or (under certain conditions) indoors. It is ideal for use in installations where a reliable source of clean indoor combustion air cannot be guaranteed.

II Speciﬁ cations

FIGURE 1: GENERAL CONFIGURATION

TABLE 1: SPECIFICATIONS

MODEL SECTIONS

CWD060 3 60 51 44 85.1 16-1/8 3 2.0 CWD083 4 82.5 71 62 85.1 19-3/4 3 2.6 CWD110 5 110 94 82 85.2 23-3/8 3 3.1 CWD138 6 137.5 118 103 85.2 27 3 3.6

CWD165 7 165 142 123 85.2 30-5/8 3 OR 4 4.2 CWD193 8 192.5 165 143 85.2 34-1/8 3 OR 4 4.7 CWD220 9 220 189 164 85.2 37-3/4 3 OR 4 5.2

CWD245 10 245 211 183 85.3 41-3/8 3 OR 4 5.8

INPUT (MBH)

DOE HTG.

CAPY (MBH)

I=B=R NET

RATING (MBH)

AFUE

(%)

FIG 1

DIM. “A” (in.)

VENT

DIA. (in.)

WATER

CONTENT

(Gal.)

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.

• 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) Read Section VI 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 VI.

3) 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.

4) Make sure that the boiler received is conﬁ gured for the correct gas (natural or LP).

5) This boiler is not designed for use with return temperatures under 120F for a sustained period of time. Some systems, such as those having large water contents, may require a return water bypass or other special provisions to protect the boiler against low return temperatures. Failure to provide such provisions if needed could result in severe corrosion damage to the boiler. For more information on when low water temperatures protection is required, and appropriate protection, see Part VIII.

6) For installations at altitudes above 2000ft, special oriﬁ ce and pressure switches are required. Make sure that the boiler is conﬁ gured for use at the correct altitude.

NOTICE

This product must be installed by a licensed plumber or gas ﬁ tter 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) Boiler clearances are shown in Figure 2. Figure 2a shows clearances from the boiler when outdoor combustion air is used. Figure 2b shows clearances from the boiler when combustion air is obtained from the boiler room. These minimum clearances apply to all types of combustible construction as well as noncombustible walls, ceilings and doors. At least 24” must be provided for servicing at the front of the boiler. This front clearance may be provided through a door, such as a closet door. Boiler will be much easier to service if at least 12” is provided from the sides and rear of the boiler to walls.

2) Clearances from venting to combustible material depends upon the type of venting, whether the vent pipe is enclosed, and whether the venting is vertical or horizontal. See Table 2 for vent clearance information.

3) Boiler may be installed on a non-carpeted combustible surface.

4) The relief valve must not be moved from the location shown in Figure 1.

5) When combustion air is obtained from the boiler room, a 10” clearance is required from the side of the boiler having the air inlet collar to combustible or non-combustible obstruction (Figure 2b).

6) The boiler should be located so as to minimize the length of the vent system.

7) Do not install this boiler in a location where gasoline or other ﬂ ammable vapors or liquids will be stored or used. Do not install this boiler in an area where large amounts of airborne dust will be present, such as a workshop. When indoor combustion air is used, do not install in a location where sources of hydrocarbons will be stored or used. Some common sources of hydrocarbons include bleaches, fabric softeners, paints, cleaners, refrigerants, and cat boxes. Traces of these substances can be drawn into the boiler causing severe corrosion damage to the boiler and /or objectionable odors.

FIGURE 2a: CLEARANCES WHEN BOILER IS DIRECT VENTED (OUTDOOR COMBUSTION AIR IS USED)

FIGURE 2b: CLEARANCES WHEN COMBUSTION AIR IS OBTAINED FROM BOILER ROOM

TABLE 2: CLEARANCES FROM VENT PIPING TO COMBUSTIBLE CONSTRUCTION

TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE

MINIMUM CLEARANCE

TO COMBUSTIBLE

MATERIAL

HEAT FAB SAF-T VENT

PROTECH FASNSEAL

PROTECH FASNSEAL W2

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

PROTECH FASNSEAL W2 VERTICAL OR HORIZONTAL ENCLOSED ON ALL FOUR SIDES 3”

HEAT FAB SAF-T VENT SC VERTICAL OR HORIZONTAL

“B” VENT CHASE USED AS PART OF

CROWN COAXIAL VENT SYSTEM*

VERTICAL OR HORIZONTAL

HORIZONTAL OR VERTICAL

WITH OFFSETS

VERTICAL WITH NO OFFSETS ENCLOSED ON ALL FOUR SIDES

VERTICAL

AT LEAST ONE SIDE OPEN,

COMBUSTIBLE MATERIAL ON A

MAXIMUM OF THREE SIDES

ENCLOSED ON ALL FOUR SIDES

UNENCLOSED OR ENCLOSED ON

ALL SIDES

PER “B” VENT MANFACTUER’S

INSTRUCTIONS

1”

8”

6”

0”

REFER TO “B” VENT MANUFACTURER’S

INSTRUCTIONS

* “B” Vent is used as a chase to carry combustion air in this system - never attempt to vent a CWD boiler using “B” vent

V Air for Combustion and Ventilation

Sufﬁ cient fresh air must be supplied for both combustion and ventilation. In general, combustion air is obtained in one of

two ways:

• Direct Vent Installations – Combustion air is piped directly to the boiler inlet collar from the outdoors. This is also sometimes called a “sealed combustion” installation.

• Direct Exhaust Installations – Combustion air is obtained from the boiler room. In some cases, openings or duct work may be run from the outdoors to the boiler room, however the ducting is not connected directly to the boiler.

Air for ventilation is required to keep various boiler components from overheating and is always obtained from indoors. To

ensure an adequate combustion and ventilation air supply, perform the following steps:

Step 1: Determine whether the boiler is to be installed in a building of unusually tight construction

A good deﬁ nition of “unusually tight construction” is construction having all of the following features:

• Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and sealed.

• Weather stripping has been added on openable windows and doors.

• Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates and ﬂ oors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and at other openings.

Step 2: Determine whether the boiler is to be installed in a conﬁ ned space

A conﬁ ned space is deﬁ ned 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 conﬁ ned 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 conﬁ ned space.

Example:

A CWD245 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 = (245000 BTU/hr + 30000 BTU/hr) / 1000 = 275 Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft 350/275 = 1.27. Since 1.27 is less than 50, the boiler room is a conﬁ ned space.

Step 3: Decide whether the boiler will be direct vented or direct exhausted

The boiler must be direct vented (combustion air piped directly to the boiler) if:

• The boiler is to be installed in a laundry room

• The building in which the boiler is installed has an indoor pool.

• The boiler is located in an area having any of the contaminants described in Section IV.

It is also strongly recommended that combustion air be piped from outside when the boiler is installed in a building of

unusually tight construction.

Step 4: If the boiler is Direct Vented, Provide Air as Follows (If Indoor Combustion Air is used,

Skip to Step 5):

1) Combustion air piping must not exceed the maximum lengths called for in Section VI.

2) Although combustion air is obtained directly from outdoors, openings may be required into the boiler room to allow for adequate equipment ventilation. The following guidelines apply regardless of whether or not the building is of unusually tight construction:

Unconﬁ ned Space– Natural inﬁ ltration into the boiler room will provide adequate air for ventilation without additional

openings into boiler room.

Conﬁ ned Space – Provide two openings into the boiler room, one near the ﬂ oor 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 ﬂ oor (Fig 3). The minimum opening dimension is 3 inches.

• If the CWD boiler is the only gas-burning appliance in the boiler room, these openings must each have a 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 regardless of opening requirements for other appliances.

• If the total volume of both the boiler room and the room to which the openings connect is less than 50 cubic feet per 1000 BTU/hr of total appliance input, install a pair of identical openings into a third room. Connect additional rooms with openings until the total volume of all rooms is at least 50 cubic feet per 1000 BTU/hr of input.

• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are used, they must be no ﬁ ner than ¼” (4 x 4) mesh.

Step 5: If Indoor Combustion Air is Used, Provide Air as Follows:

1) Buildings of other than unusually tight construction: Unconﬁ ned Space– Natural inﬁ ltration into the boiler room will normally provide adequate air for combustion and

ventilation without additional louvers or openings into boiler room.

Conﬁ ned Space – Provide two openings into the boiler room, one near the ﬂ oor 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 ﬂ oor (Fig 3).

• Each opening must have a free area of 1 square inch per 1000 BTU/hr input of all gas burning appliances in the boiler room. The minimum opening dimension is 3 inches. Minimum opening free area is 100 square inches per opening.

• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are used, they must be no ﬁ ner than ¼” (4 x 4) mesh.

2) Buildings of unusually tight construction: If at all possible, direct vent the boiler. Where the boiler must be installed in unusually tight construction and cannot be

direct vented, openings must be installed between the boiler room and the outdoors or a ventilated space, such as an attic or crawl space, which communicates directly with the outdoors. Two openings are required. The top edge of the upper opening must be within 12 inches of the ceiling. The bottom edge of the lower opening must be within 12 inches of the ﬂ oor. Size openings and ducts as follows:

• Vertical ducts or openings directly outdoors (Fig 4, Fig 5, Fig 6) – Each opening must have a free cross sectional area of 1 square inch per 4000 BTU/hr of the total input of all gas-ﬁ red appliances in the boiler room but not less than 100 square inches. Minimum opening size is 3 inches.

• Openings to outdoors via horizontal ducts (Fig 7) - Each opening must have a free cross sectional area of 1 square inch per 2000 BTU/hr of the total input of all gas ﬁ red appliances in the boiler room but not less than 100 square inches. Minimum opening size is 3 inches.

• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are used, they must be no ﬁ ner than ¼” (4 x 4) mesh.

FIGURE 3: BOILER INSTALLED IN A CONFINED SPACE - VENTILATION OR COMBUSTION / VENTILATION AIR FROM INSIDE

FIGURE 4: ALL AIR FROM OUTSIDE USING VENTILATED CRAWL SPACE AND ATTIC

FIGURE 5: ALL AIR FROM OUTSIDE USING VENTILATED ATTIC

FIGURE 6: ALL AIR FROM OUTSIDE USING OPENINGS INTO BOILER ROOM

FIGURE 7: ALL AIR FROM OUTSIDE USING HORIZONTAL DUCTS INTO BOILER ROOM

VI Venting

WARNING

Failure to vent this boiler in accordance with these instructions could result in unreliable boiler operation, severe damage to the boiler or property, or unsafe operation:

* Do not attampt to vent this boiler with galvanized, PVC, or any other vent system not listed in Table 4. * Do not attempt to mix components from different approved vent systems. * Do not install a barometric damper or drafthood on this boiler. * Do not attempt to use the vent system for this boiler with any other appliance. * 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 three basic ways to vent the CWD boiler:

• Horizontal (“side wall”) Venting - Vent system exits the building through an outside wall. Combustion air is either

obtained through a separate pipe from outside (a “direct vent” installation) or obtained from the boiler room (a “direct exhaust” installation).

• Vertical Non-Coaxial Venting - Vent system exits the building through a roof. Combustion air is either obtained

through a separate pipe from outside (a “direct vent” installation) or obtained from the boiler room (a “direct exhaust” installation).

• Vertical Coaxial Venting - Vent system exits the building through a roof. A portion of the vent system is coaxial, meaning

that it consists of a “pipe within a pipe”. Flue gasses exit the building through the inner pipe and combustion air is drawn through the space between the two pipes.

For each of the above three basic methods, there are several variations, resulting in a total of 13 options for venting

the CWD boiler. A description of each of these venting options is listed in Tables 3a - 3c. For clarity, these vent options are numbered from 1 to 13 in Table 3. One of the vent option columns in Table 3 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 Table 4. These systems are made of a special stainless steel alloy (AL29-4C) for protection against corrosive ﬂ ue gas condensate. They are also designed to provide a gas tight seal at all joints and seams so that ﬂ ue gas does not enter the building. Each approved vent system has unique method for installation - do not attempt to mix components from different vent systems. The only exceptions are:

• Heat Fab Saf-T Vent SC may be combined with Saf-T Vent EZ Seal.

• Protech FasNSeal W2 may be combined with Protech FasNSeal.

See the vent installation section of this manual for information on how this can be done. Heat Fab Saf-T Vent SC is a double wall vent system which can be used in two ways on CWD installations. In vertical

coaxial vent systems (Vent Options 12 and 13), the space between the inner and outer pipes is used as a conduit to bring combustion air to the boiler. In Horizontal (Vent Options 1 to 5) and Vertical (Option 6 to 10) vent systems, Saf-T Vent SC can be used to obtain a 0” clearance to combustible construction. When this is done, the space between the inner and outer pipes is used for ventilation, but boiler combustion air comes from elsewhere.

Protech FasNSeal W2 is also a double wall vent system. In some cases, it can used to obtain closer clearances to

combustible construction than are possible using Protech FasNSeal (see Table 2). The space between the inner and outer pipes on FasNSeal W2 cannot be used as a combustion air conduit.

The Crown Vertical coaxial vent system (Vent Option 11) is similar to that constructed using Heat Fab Saf-T Vent SC

except it is constructed by running one of the 3” single wall vent systems shown in Table 4 inside 5” type “B” vent. The space between the 3” vent and the “B” vent forms a conduit to bring combustion air to the boiler. The advantage of this system is that it can be constructed using any of the vent systems shown in Table 4 except for Heat Fab Saf-T Vent SC and Protech FasNSeal W2. No turns are permitted in the coaxial section of this system.

TABLE 3a: SUMMARY OF HORIZONTAL VENTING OPTIONS

VENT OPTION # 12345

CLASSIFICATION USED IN THIS MANUAL

ILLUSTRATED IN FIGURE 8a OR 8b 8a OR 8b 9 9

HORIZONTAL DIRECT VENT

(RESERVED

FOR FUTURE

USE)

HORIZONTAL

DIRECT

EXHAUST

HORIZONTAL

DIRECT

EXHAUST

VENT PIPE STRUCTURE PENETRATION

AIR INTAKE PIPE STRUCTURE PENETRATION

VENT PIPE SIZE 3” 4” 3” 4” AIR INTAKE PIPE SIZE 4” 4” N.A. N.A.

CWD060 - CWD138 55 FT CWD165 35 FT CWD193 25 FT CWD220 15 FT

PIPE LENGTH

MAXIMUM VENT

MAXIMUM

INTAKE PIPE

EXHAUST TERMINAL

AIR INTAKE TERMINAL

VENT MATERIAL APPROVED VENT SYSTEM SHOWN IN TABLE 4 AIR INTAKE MATERIAL GALVANIZED OR PVC N.A. N.A.

CWD245 N.R. CWD060 - CWD138 60 FT 60 FT N.A. N.A.

CWD165 40 FT 60 FT N.A. N.A. CWD193 30 FT 60 FT N.A. N.A. CWD220 20 FT 60 FT N.A. N.A.

LENGTH

CWD245 N.R.

WALL WALL WALL WALL

WALL WALL N.A. N.A.

55 FT 55 FT 55 FT 55 FT 35 FT 55 FT 55 FT 25 FT 55 FT 55 FT 15 FT 55 FT

55FT 10 FT 55 FT

60 FT N.A. N.A.

3” 90 ELBOW,

TEE, OR CROWN

COAXIAL

TERMINAL

#50-003

4” 90 ELBOW

OR CROWN

COAXIAL

TERMINAL

#50-003

4” 90 ELBOW,

TEE, OR CROWN

COAXIAL

TERMINAL

#50-004

4” 90 ELBOW

OR CROWN

COAXIAL

TERMINAL

#50-004

3” 90 ELBOW

OR TEE

N.A. N.A.

4” 90 ELBOW

OR TEE

“N.R” - Not recommended “N.A.” - Not applicable

FIGURE 8a: HORIZONTAL DIRECT VENTING USING SEPARATE TERMINALS (VENT OPTIONS 1-2)

FIGURE 8b: HORIZONTAL DIRECT VENTING USING COAXIAL TERMINAL (VENT OPTIONS 1-2)

FIGURE 9: HORIZONTAL DIRECT EXHAUST VENT SYSTEM (VENT OPTIONS 4,5)

2) Maximum Vent and Air Intake Lengths - The maximum length of the vent air intake piping depends upon the vent option selected, the vent pipe size, and the boiler size. See Table 3 for the maximum vent length. In addition to the maximum length of piping shown in Table 3, the following ﬁ ttings may also be used:

• Horizontal Vent Systems: One 90 deg. elbow

• Vertical Vent Systems: Two 90 deg. elbows

• Vertical Coaxial Vent Systems: Two 90 deg. elbows

• Air Intake Systems: Two 90 deg. elbows

If additional elbows are desired, the maximum allowable vent length must be reduced by the amount shown in Table 5 for

each additional elbow used. Note: Termination ﬁ ttings do not need to be counted when counting additional elbows.

Example:

A 3” vent system is planned for a horizontal direct vented CWD165 which has the following components: 2 ft vertical pipe

1 90 elbow 5 ft horizontal pipe 1 90 elbow 3 ft horizontal pipe 1 45 elbow 4 ft horizontal pipe 1 termination elbow

The Vent Option #1 column in Table 3a describes a horizontal direct vent system using 3” vent pipe. From this column, we

see that a CWD165 may vent length of up to 35ft. The ﬁ rst 90 elbow and the termination elbow are not considered. From Table 5, the equivalent length of the 3” 45 elbow is 4ft and the equivalent length of the 3” 90 degree elbow is 5.5ft. The maximum allowable run of straight pipe on this system is therefore:

35ft – 4 ft – 5.5ft = 25.5ft Since the planned installation has only 14 ft of straight pipe, the planned vent length is acceptable.

3) Minimum Vent / Exhaust Pipe Length - Minimum vent length is 2ft. Minimum air inlet length is 0ft.

3) Permitted Terminals for Horizontal Venting (Vent Options 1 - 5) - Table 3a shows permitted types of terminals for both the

vent and air inlet systems. On horizontal direct vent systems using 4” air inlet pipe (Vent Options 1 and 2), the following Crown co-axial terminals may be used. These terminals have the advantage of requiring only one wall penetration. Part numbers for the Crown coaxial terminals are as follows:

• 3” Vent - 50-003

• 4” Vent - 50-004

When separate vent and air intake terminals are used, or when the boiler uses indoor combustion air, the vent terminal

is either a tee or an elbow supplied by the vent system manufacturer and equipped with a rodent screen. Vent system manufacturer’s part numbers for these ﬁ ttings are shown in Table 4. In some cases, the elbows and tees shown in Table 4 require separate adaptors and/or rodent screens. When this is the case, vent manufacturer part numbers for these additional parts are shown in Table 4 along with the termination ﬁ tting.

When Heat Fab Saf-T Vent SC is used, the Heat Fab 5300CI or 5400CI ﬁ tting is used between the last piece of Saf-T

Vent CI and the terminal. These ﬁ ttings physically adapt from the CI pipe to the terminal and also provide ventilation openings which must remain open for the Saf-T Vent CI to maintain its clearance rating.

Except when the Crown 50-003 or 50-004 coaxial terminals are used, the air intake ﬁ tting on a horizontal direct vent

system (Options 1 - 2) is always a 90 degree elbow with a rodent screen. 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 8a.

4) Horizontal vent terminal location - Observe the following limitations on the vent terminal location (also see Fig 15a - d):

• Direct exhaust installations (installations using indoor combustion air) - Exhaust terminal must be at least 4 feet below or 4 feet horizontally from any window, door, or gravity air inlet into the building.

• Direct vent installations – Exhaust elbow or coaxial terminal must be at least 1 foot from any door, window, or gravity inlet into the building.

• Direct vent installations using termination elbows – Maintain the correct clearance and orientation between the inlet and exhaust elbows. The elbows must be at the same level and their center lines must be between 12 and 36 inches apart.

• The bottom of the exhaust elbow, tee, or coaxial 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 exhaust elbow, tee, or coaxial terminal must be at least 7 feet above a public walkway.

• The bottom of the exhaust elbow, tee, or coaxial terminal must be at least 3 feet above any forced air inlet located within 10 feet.

• A clearance of at least 4 feet horizontally or 4 feet vertically must be maintained between the exhaust terminal and gas meters, electric meters, regulators, and relief equipment.

• Do not locate the terminal under decks or similar structures.

• Top of exhaust elbow, tee, or coaxial terminal must be at least 4 feet below eves, sofﬁ ts, or overhangs. Overhang may not exceed 3 feet (Figure 15d).

• Terminal must be at least 3 feet from an inside corner.

• Under certain conditions, water in the ﬂ ue gas may condense on the structure in areas around the terminal. If these areas are made of materials subject to damage by ﬂ ue gas condensate, they should be protected.

• If possible, install the terminal on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if the terminal is subjected to winds in excess of 40 mph.

• The noise level in the vicinity of the terminal is approximately 65 dB (roughly the level of a normal conversation). Avoid positioning the terminal in areas where this might be objectionable.

5) Horizontal air intake terminal location - Horizontal air intake terminal must be at least 12” above the normal snow line.

6) Permitted Terminals for Vertical Venting (Vent Options 6 - 10) - Terminals used on these systems are caps. Vent manufacturer part numbers for these caps are shown in Table 4. When Heat Fab Saf-T Vent SC is used, the 5300CI or 5400CI ﬁ tting is used between the highest piece of Saf-T Vent CI and the cap. These ﬁ ttings physically adapt from the CI pipe to the cap and also provide ventilation openings which must remain open for the Saf-T Vent CI to maintain its clearance rating.

Vertical direct vent systems (Vent Options 6 - 8) can have combustion air obtained from either a vertical or horizontal air

intake system. When combustion air is obtained from the roof, the air inlet terminal consists of a 180 degree elbow (or two 90 degree elbows) with a rodent screen as shown in Figure 10. When combustion air is obtained through a horizontal vent system, the air inlet termination is a 90 degree elbow with a rodent screen as shown in Figure 8a.

7) Permitted terminals for Vertical Coaxial Venting (Options 11 - 13) - When the Crown vertical coaxial vent kit is used (Vent Option 11), a cap compatible with the vent system is used (Figure 12, Table 4). The concentric air intake hood supplied in the Crown kit is the air inlet terminal (Figure 12).

When vertical coaxial venting is done using Heat Fab Saf-T Vent SC (Options 12, 13), the vent terminal is a SC03VT or

SC04VT terminal installed with a 5300CI or 5400CI adaptor. The openings in this adaptor are used for combustion air.

TABLE 3b: SUMMARY OF VERTICAL VENTING OPTIONS

VENT OPTION # 678910

CLASSIFICATION USED IN THIS MANUAL

ILLUSTRATED IN FIGURE 10 10 11 11

VERTICAL

DIRECT VENT

VERTICAL

DIRECT VENT

(RESERVED

FOR FUTURE

USE)

VERTICAL

DIRECT

EXHAUST

VERTICAL

DIRECT

EXHAUST

VENT PIPE STRUCTURE PENETRATION

AIR INTAKE PIPE STRUCTURE PENETRATION

VENT PIPE SIZE 3” 4” 3” 4” AIR INTAKE PIPE SIZE 4” 4” N.A. N.A.

CWD060 - CWD138 47 FT CWD165 27 FT CWD193 17 FT CWD220 N.R.

PIPE LENGTH

MAXIMUM VENT

MAXIMUM

INTAKE PIPE

EXHAUST TERMINAL BY VENT SYSTEM MANUFACTURER. SAME DIAMETER AS VENT SYSTEM. SEE TABLE 4. AIR INTAKE TERMINAL

(ROOF PENETRATION) AIR INTAKE TERMINAL

(WALL PENETRATION) VENT MATERIAL APPROVED VENT SYSTEM SHOWN IN TABLE 4 AIR INTAKE MATERIAL GALVANIZED OR PVC N.A. N.A.

“N.R” - Not recommended “N.A.” - Not applicable

CWD245 N.R. CWD060 - CWD138 52 FT 50 FT N.A. N.A.

CWD165 32 FT 50 FT N.A. N.A. CWD193 22 FT 50 FT N.A. N.A. CWD220 N.R. 50 FT N.A. N.A.

LENGTH

CWD245 N.R.

ROOF ROOF ROOF ROOF

ROOF OR WALL ROOF OR WALL N.A. N.A.

47 FT 47 FT 47 FT 47 FT 27 FT 47 FT 47 FT 17 FT 47 FT 47 FT N.R. 47 FT 47 FT N.R. 47 FT

50 FT N.A. N.A.

4” 180 ELBOW 4” 180 ELBOW N.A. N.A.

4” 90 ELBOW 4” 90 ELBOW N.A. N.A.

8) Vertical Vent Terminal Locations (Vent Options 6 - 13) - Observe the following limitations on the location of all vertical vent terminals (see Figs. 10, 11, 12, 13):

• The lowest discharge opening on the cap must be at least 2 feet above any object located within 10 feet.

• If outside air is used for combustion (Options 6-7, 11-13), the vertical distance between 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.

9) Terminal offsets - Horizontal elbow or tee terminals may be offset by as much as 5 ft as shown in Figure 14. This sometimes helps maintain the 12” minimum clearance required above the snow line. The extra two elbows and the section of vertical pipe on the outside of the building must be counted when checking that the maximum vent / intake pipe length is not exceeded. On horizontal direct vent systems, both terminals must be offset by the same amount so that their relationship to one another is the same as shown in Figure 8a. When this offset is used, the horizontal section of vent pipe must be pitched away from the outside so that condensate cannot collect in the lower offset elbow.

10) Wall thimbles – Wall thimbles are required where the vent pipe passes through combustible walls with less than the required clearance shown in Table 2 or as required by local codes. Vent manufacturer’s wall thimble part numbers are shown in Table 4.

11) Condensate Traps and Pitch of Horizontal piping – All horizontal vent piping must be pitched ¼” per foot so that any condensate which forms in this piping will run towards either the outdoors or into a condensate trap. Vent manufacturer’s part numbers for suitable condensate traps are shown in Table 4.

All vertical vent systems must include at least one condensate trap as shown in Figures 10-13. This will collect any

condensate that forms in the vent system as well as any rain water that gets around the vent cap.

The maximum allowable vertical run directly off of the boiler without a condensate trap is 7.5 ft (Figure 16). Install a

condensate trap in longer vertical runs so that condensate which might form in this ﬁ rst vertical section will not run into the boiler fan.

FIGURE 10: VERTICAL NON-COAXIAL DIRECT VENT SYSTEM (VENT OPTIONS 6, 7)

FIGURE 11: VERTICAL DIRECT EXHAUST SYSTEM (VENT OPTIONS 9, 10)

TABLE 3c : SUMMARY OF VERTICAL COAXIAL VENTING OPTIONS

VENT OPTION # 11 12 13

CLASSIFICATION USED IN THIS MANUAL

VENT PIPE STRUCTURE PENETRATION

AIR INTAKE PIPE STRUCTURE PENETRATION

VENT PIPE SIZE 3” 3” 4” AIR INTAKE PIPE SIZE

(NON-COAXIAL SECTION)

AIR INTAKE PIPE SIZE

(COAXIAL SECTION)

CWD060 - CWD138 47 FT CWD165 27 FT 27 FT

CWD193 N.R. N.R. CWD220 N.R. N.R.

PIPE LENGTH

MAXIMUM VENT

MAXIMUM LENGTH COAXIAL SECTION

MAXIMUM

INTAKE PIPE

EXHAUST TERMINAL

AIR INTAKE TERMINAL

ADAPTOR FROM NON-COAXIAL TO COAXIAL SECTIONS

VENT MATERIAL (NON-COAXIAL SECTION)

VENT MATERIAL (COAXIAL SECTION)

AIR INTAKE MATERIAL (NON-COAXIAL SECTION)

AIR INTAKE MATERIAL (COAXIAL SECTION)

“N.R” - Not recommended “N.A.” - Not applicable

CWD245 N.R. N.R.

CWD060 - CWD138 52 FT 50 FT 50 FT CWD165 32 FT 32 FT CWD193 N.R. N.R.

LENGTH

CWD220 N.R. N.R. CWD245 N.R. N.R.

DIRECT VENT

30 FT OR AS

LIMITED BY MAX

VENT LENGTH,

WHICHEVER IS

TURER. SAME DIAMETER AS

VENT SYSTEM.

SEE TABLE 4.

SUPPLIED WITH CROWN #500005

COAXIAL VENT

TEE + SUPPORT SUPPLIED WITH CROWN #500005

COAXIAL VENT

VENT SYSTEM

VERTICAL

COAXIAL

ROOF ROOF ROOF

4” 4” 4”

5”

LESS

BY VENT

SYSTEM

MANUFAC-

KIT

5” “B” VENT

KIT

APPROVED

SHOWN IN

TABLE 4

APPROVED

SHOWN IN

TABLE 4

5” TYPE “B”

VENT

VERTICAL

COAXIAL

DIRECT VENT

5” 7”

47 FT 47 FT

AS LIMITED

BY MAX VENT

LENGTH

HEAT FAB

#SC03RC

HEAT FAB

#SC03VT

HEAT FAB

#SC03TAD4

HEAT FAB

SAF-T VENT

HEAT FAB

SAF-T VENT SC

GALVANIZED OR PVC

HEAT FAB

SAF-T VENT SC

VERTICAL

COAXIAL

DIRECT VENT

CONSULT

FACTORY

CONSULT FACTORY

CONSULT

FACTORY

HEAT FAB

#SC04RC

HEAT FAB

#SC04VT

HEAT FAB

#SC04TAD4

HEAT FAB

SAF-T VENT

HEAT FAB

SAF-T VENT SC

HEAT FAB

SAF-T VENT SC

FIGURE 12: VERTICAL COAXIAL DIRECT VENT USING CROWN #500005 VENT KIT (VENT OPTION 11)

FIGURE 13: VERTICAL COAXIAL DIRECT VENT USING HEAT FAB SAF-T VENT SC (VENT OPTIONS 12, 13)

TABLE 4: PERMISSIBLE VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS

MANUFACTURER VENT SYSTEM SIZE

SAF-T VENT

EZ SEAL

HEAT FAB

SAF-T VENT SC

FASNSEAL

PROTECH SYSTEMS

INC.

FASNSEAL W2

SVE

Z-FLEX

METAL-FAB CORR/GUARD

SERIES III

(“Z-VENT III”)

3 FSHDT3 FSWT3

3 SVEDWCF03 2SVSWTEF03

4 SVEDWCF04 2SVSWTEF04

3 CGSWDS(3”) CGSWWPK(3”)

4 CGSWDS(4”) CGSWWPK(4”)

CONDENSATE

TRAP

9321

(NOTE 3)

9421

(NOTE 3)

SC03DRN

(NOTE 3)

SC04DRN

(NOTE 3)

FSHDT4

OR FSCD4

(NOTE 4)

W2-T3

+W2-DF3

W2-T4

+ W2-DF4

WALL

THIMBLES

7393GC

7393GCS

5391CI

7493GC

7493GCS

5491CI

SC03FS

SC03FSA

SC04FS

SC04FSA

FSWT4

W2-WT3

W2-WT4

HORIZONTAL

TERMINATION

ELBOW: 7314TERM TEE: 7390TEE 5300CI

ELBOW: 7414TERM TEE: 7490TEE

ELBOW (NOTE 5): SC03HT + 7314TERM TEE (NOTE 5): SC03HT + 7390TEE

ELBOW (NOTE 5): SC04HT + 7414TERM TEE (NOTE 5): SC04HT + 7490TEE

ELBOW: FSELB9003 + FSBS3 TEE: FSTT3

ELBOW: FSELB9004 + FSBS4 TEE: FSTT4

ELBOW: FSA-SWDW3 + FSELB9003 + FSBS3 TEE: FSA-SWDW3 + FSTT3

ELBOW: FSA-DWSW4 + FSELB9004 + FSBS4 TEE: FSA-SWDW4 + FSTT4

ELBOW: 2SVSTEX0390 TEE: 2SVSTTF03

ELBOW: 2SVEEWCF0490 + 2SVSTPF TEE: 2SVSTTF04

ELBOW: CGSW90LTM(3”) TEE: CGSWTTM(3”)

ELBOW: CGSW90LTM(4”) TEE: CGSWTTM(4”)

VERTICAL

TERMINATION

5400CI

5300CI + SC03VT

(NOTE 6)

5400CI

+ SC04VT

(NOTE 6)

FSRC3

FSRC4

W2-RC3

W2-RC4

2SVSRCF03

2SVSRCF04

CGSWC(3”)

CGSWC(4”)

NOTES:

1) See vent system manufacturer’s literature for other part numbers that are required such as straight pipe, elbows, ﬁ restops and vent supports.

2) In addition to terminals shown, Crown coaxial terminals may be used in some cases. See Table 3 for applications and Crown part numbers.

3) All Heat Fab condensate traps shown may be installed in vertical or horizontal run.

4) Protech FSCD4 condensate trap may be installed in a vertical or horizontal run. All other Protech traps must be installed in a horizontal run only.

5) Heat Fab Saf-T Vent SC may not be used for horizontal coaxial venting - a separate air inlet pipe must be provided for horizontal direct vent systems. SC03HT or SC04HT adapters are used to adapt from SC pipe to terminal. Use of SC pipe in horizontal systems does allow for reduced clearances to combustibles in some applications. See Table 2.

6) Heat Fab SC03VT or SC04VT adapters are required on any vertical vent system using Saf-T Vent SC even when combustion air is obtained through a separate pipe or from the boiler room.

7) Metal-Fab CGSWDS condensate traps may only be installed in a horizontal run.

12) Vertical and horizontal sections of piping must be properly supported. See vent system manufacturer’s instructions for more information.

13) Non-coaxial vent piping must be accessible for periodic inspection.

14) Fire stops and wall thimbles – Use ﬁ re stops where required by code or by the vent system manufacturer. Consult vent system manufacturer’s literature for information on suitable ﬁ re stops.

15) Supports - Vertical and horizontal sections of vent pipe must be properly supported. See the Vent System assembly section of this manual for more information.

B. Removing an Existing Boiler From a Common Chimney

Read this only if the CWD boiler is replacing an existing boiler that is being removed from a common chimney. This

section does not apply to the installation of a CWD 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 deﬁ ciencies 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 ﬁ replace 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 ﬂ ame 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, ﬁ replace 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 resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1.

NEVER COMMON VENT A CWD BOILER WITH OTHER APPLIANCES

TABLE 5a: VENT FITTING EQUIVALENT LENGTH

VENT FITTING EQUIVALENT

LENGTH (ft)

3” 90 ELBOW 5.5 3” 45 ELBOW 4.0

HEAT FAB SC03E90 (3” COAXIAL 90 ELBOW)

HEAT FAB SC03E45 (3” COAXIAL 45 ELBOW)

4” 90 ELBOW 8.0 4” 45 ELBOW 4.5 HEAT FAB SC04E90

(4” COAXIAL 90 ELBOW) HEAT FAB SC04E45

(4” COAXIAL 45 ELBOW

5.5

4.0

8.0

4.5

WARNING

TABLE 5b: AIR INTAKE FITTING EQUIVALENT LENGTH

INTAKE FITTING EQUIVALENT

LENGTH (ft)

4” 90 ELBOW 8.0 4” 45 ELBOW 4.5

HEAT FAB SC03E90 (3” COAXIAL 90 ELBOW)

HEAT FAB SC03E45 (3” COAXIAL 45 ELBOW)

HEAT FAB SC04E90 (4” COAXIAL 90 ELBOW)

HEAT FAB SC04E45 (4” COAXIAL 45 ELBOW)

CONSULT CROWN

FIGURE 14: HORIZONTAL TERMINAL OFFSETS

FIGURE 15a: LOCATION OF DIRECT VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE

FIGURE 15b: LOCATION OF DIRECT EXHAUST TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE

FIGURE 15c: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS

FIGURE 15d: POSITIONING VENT TERMINAL UNDER OVERHANGS

FIGURE 16: USE OF CONDENSATE TRAPS

C. Vent / Intake System Assembly

1) General Assembly Notes: a) Where the use of “silicone” is called for in the following instructions, use GE RTV 106 for the vent collar and coaxial

terminal. Air inlet piping sections are sealed with any general-purpose silicone sealant such as GE RTV102. PVC air inlet

piping sections are connected with PVC cement. b) Longitudinal welded seams should not be placed at the bottom of horizontal sections of exhaust pipe. c) Do not drill holes in vent pipe. d) Do not attempt to mix vent components of different vent system manufacturers. e) In some cases, there are differences between the vent system installation instructions in this manual and those in the

vent system manufacturer’s manual. Where such differences exist, this manual takes precedence over the vent system

manufacturer’s manual.

CAUTION

Vent systems made by Heat Fab, Protech, and Z-Flex rely on gaskets for proper sealing. When these vent systems are used, take the following precautions:

• Make sure that gasket is in position and undamaged in the female end of the pipe.

• Make sure that both the male and female pipes are free of damage prior to assembly.

• Only cut vent pipe as permitted by the vent manufacturer in accordance with their instructions. When pipe is cut, cut end must be square and carefully deburred prior to assembly.

2) Vent Collar Installation – The vent collar is shipped loose in the accessory bag along with two collar gaskets, the outlet oriﬁ ce, and four 10-32 mounting screws. Verify that the 6 digit part number model number marked on the outlet exhaust oriﬁ ce matches that shown in Table 6. Mount the collar and oriﬁ ce as shown in Figure 17. If desired, the ﬁ rst piece of exhaust pipe can be connected to the collar before mounting the collar on the boiler.

+ 54 hidden pages

Crown Boiler CWD220, CWD083, CWD110, CWD193, CWD245 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual