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BWC070, BWC090, BWC120
Installation Manual Supplement
th
June 12 , 2007
The following pages are copied from the latest edition of the installation manual for
the above boilers, which is not yet in print. These pages cover new vent options that have
been added for these boilers and which are not shown in the current manual. These
options include:
1) 80/125mm concentric venting may be used to achieve longer vent runs.
2) 80/125mm concentric venting may be used for vertical
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VII Venting WARNING FAILURE TO VENT THIS BOILER IN ACCORDANCE WITH THESE INSTRUCTIONS COULD CAUSE FLUE GAS TO ENTER THE BUILDING RESULTING IN SEVERE PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH: * Do not attempt to vent this boiler with galvanized, PVC, or any other vent components not listed in Table 7.4. * Do not attempt to mix components from different approved vent systems. * Do not obtain combustion air from within the building. * Do not install a barometric damper or drafthood on this boi
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2) Maximum Vent and Air Intake Lengths - The maximum length of the vent air intake piping depends upon the vent option selected and the boiler size. See Table 7.1 or 7.9 for the maximum vent length. In horizontal vent systems, the lengths shown in Table 7.1 are in addition to the first standard elbow on top of the boiler. For vertical vent systems, the maximum vertical vent lengths shown in Table 7.9 are in addition to two standard radius elbows. If more elbows are desired, the maximum allo
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Horizontal Terminal Clearance Requirements (continued): • Vent terminal must be at least 6 feet from an inside corner. • Under certain conditions, water in the flue gas may condense, and possibly freeze, on objects around the vent terminal including on the structure itself. If these objects are subject to damage by flue gas condensate, they should be moved or protected. • If possible, install the vent and air intake terminals on a wall away from the prevailing wind. Reliable operation of this
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FIGURE 7.2: HORIZONTAL CONCENTRIC VENTING (VENT OPTION 1,3) FIGURE 7.3: HORIZONTAL TWIN PIPE VENTING (VENT OPTION 2) 14
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TABLE 7.4a: CROWN CONCENTRIC 60/100 VENT COMPONENTS (VENT OPTION 1) USED ON CROWN PN DESCRIPTION SIZE VENT COMMENTS OPTION # 80/125 x 60/100mm REDUCING 80/125 x 230521 1 INCLUDED WITH STANDARD BOILER ELBOW 60/100mm 230520 TERMINAL SECTION 60/100mm 1 INCLUDED WITH STANDARD BOILER 230522 WALL GROMMET 60/100mm 1 INCLUDED WITH STANDARD BOILER 230505 39” STRAIGHT 60/100mm 1 OPTIONAL - MAY NOT BE CUT 230504 78” STRAIGHT 60/100mm 1 OPTIONAL - MAY NOT BE CUT 230506 19 1/2” STRAIGHT 60/100mm 1 OPTIONA
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6) Permitted Terminals for Vertical Venting - • Vent Option 5 - A straight termination is installed in the end of the vent pipe. Vent manufacturer part numbers for these screens are shown in Table 7.5. The air inlet terminal consists of a 180 degree elbow (or two 90 degree elbows) with a rodent screen as shown in Figure 7.10. • Vent Option 6 - Use Crown PN 230532 with the appropriate flashing (Table 7.4b) 7) Vertical Vent Terminal Locations (Vent Options 5,6) - Observe the following li
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FIGURE 7.6a: LOCATION OF VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE FIGURE 7.6b: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS FIGURE 7.6c: POSITIONING VENT TERMINAL UNDER OVERHANGS 17
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9) Pitch of Horizontal Piping - Pitch all horizontal piping so that any condensate which forms in the piping will run towards the boiler: • Pitch Crown horizontal concentric venting 5/8” per foot • Pitch Stainless steel venting 1/4” per foot. 10) Supporting Pipe - Vertical and horizontal sections of pipe must be properly supported: • Support Crown concentric venting near the female end of each straight section of pipe. Exception: Vertical runs of concentric pipe in an unused chinmey
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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 VERTICAL VERTICAL MANUAL TWIN PIPE CONC
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FIGURE 7.10: VERTICAL TWIN PIPE VENT SYSTEM (VENT OPTION 5) FIGURE 7.11: VERTICAL CONCENTRIC VENT SYSTEM (VENT OPTION 6) 20
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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 c
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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
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FIGURE 7.20: INSTALLATION OF REDUCING ELBOW ON CONCENTRIC BOILER COLLAR FIGURE 7.21: DIMENSION “L” 23
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6) Use locking bands provided to join adjacent sections of non-cuttable pipe as well as fittings. The male end of the terminal section and other cuttable sections must be held to the female end of the adjoining pipe with at least three #10 x 1/2” sheet metal screws. Drill a 1/8 hole through both outer pipes to start this screw. Use a drill stop or other means to ensure that the drill bit does not penetrate more than 3/8” into the outer pipe. Do not use a sheet metal screw longer than 1/2”.
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FIGURE 7.24: PREPARING 60/100mm TERMINAL SECTION FOR INSTALLATION IN THE WALL FIGURE 7.25: ATTACHING 60/100mm TERMINAL SECTION 25
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D. Assembly of Crown 80/125mm Concentric Venting (IMPORTANT - See Section C for 60/100mm 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
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To cut the straight sections listed above refer to Figure 7.31 and the following instructions: a) Determine the required length of the outer pipe. When doing this allow an additional 1” of length for insertion into the female end of the adjoining pipe. Mark the cut line on the outer pipe. b) Remove the plastic inner pipe by pulling it out from the female end. c) Cut the OUTER PIPE ONLY at the point marked in Step (a) using aviation shears, a hacksaw, or an abrasive wheel cutter. Be car
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3) Joining Pipe - a) Start assembly of the vent system at the boiler. Lubricate the brown gasket in the boiler vent collar with a few drops of water. b) Push the male end of the first fitting into the boiler collar until it bottoms out. The male end of cuttable sections should go 1” into the collar until the insertion mark (made in Step 2d above) is covered. On other fittings, the bead on the male pipe will be bottom out on the collar (Figure 32). c) The male end of cuttable fittings must be
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4) 80/125mm Horizontal Terminal Installation - a) Cut a 5-1/2” diameter hole through the exterior wall at the planned location of the horizontal terminal. b) Measure distance “L” from the outside surface of the exterior wall to the end of the last fitting as shown in Figure 7.33a. c) Add 1-1/4” to distance “L”. Carefully mark this length on the pipe as shown in Figure 7.33b. d) Remove the plastic inner pipe from the terminal, by gently pulling on it from the male end. Set aside. e) Cut the out
