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D ESIGNED T O L EAD
BWC Series
Direct Vent Condensing Boilers
InStallatIon SUPPlEMEnt FoR BoIlERS
VEntED WItH CPVC/PVC PIPE
These instructions must be affixed on or adjacent to the boiler.
Models:
WaRnIng: Improper installation, adjustment, alteration,
• BWC070
service or maintenance can cause property damage, injury,
or loss of life. For assistance or additional information, con-
• BWC090
sult a qualified installer, service agency or the gas supplier.
• BWC120
This boiler requires a
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1
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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 1
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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 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 fittings. • Do not intercha
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TABLE 1.1: SUMMARY OF HORIZONTAL VENTING OPTIONS VENT OPTION # 1 2 3 4 CLASSIFICATION USED IN THIS HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL MANUAL TWIN PIPE TWIN PIPE TWIN PIPE TWIN PIPE ILLUSTRATED IN FIGURE 1.2 1.3 1.4 1.4 VENT PIPE PENETRATION WALL WALL WALL WALL THROUGH STRUCTURE AIR INTAKE PIPE PENETRATION WALL WALL WALL WALL THROUGH STRUCTURE VENT PIPE SIZE 3” 3” 3” 4” 3” 3” AIR INTAKE PIPE SIZE 4” 4” BWC070 100ft 100ft BWC090 100ft 100ft BWC120 100ft 100ft BWC151 100ft 100ft BWC1
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2. Approved vent components and materials - The adaptor kits listed in Table 1.5 are required to connect the venting to the boiler. Starting at the boiler, the first 30 inches of the vent system, and the first 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 supp
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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) 4 5
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6. Horizontal Vent and Air Intake Terminal Location - 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
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FIGURE 1.4: HORIZONTAL CPVC/PVC VENTING, BWC150/225 (Vent Option #3, 4) TABLE 1.5: CROWN CPVC/PVC VENTING COMPONENTS USED ON CROWN PN DESCRIPTION VENT COMMENTS OPTION # 230595 CPVC/PVC VENT KIT, BWC070/090/120/151 1,2,5,6 230596 CPVC/PVC VENT KIT, BWC150 3,7 230597 CPVC/PVC VENT KIT, BWC225 4,8 230873 PVC CONCENTRIC TERMINAL 2,6 Use with BWC070/090/120/151 Only Note: BWC070/090/120/151 may be ordered with components in 230595 vent kit packaged inside the boiler carton. 4. Pitch of Horizontal
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TABLE 1.6: CROWN CPVC/PVC VENT KIT CONTENTS QTY PER VENT KIT CROWN PN DESCRIPTION SIZE PN 230595 PN 230596 PN 230597 (BWC070/090/120/151) (BWC150) (BWC225) 230840 CPVC/PVC VENT/INTAKE ADAPTOR 3” 1 0 0 230843 CPVC VENT ADAPTOR 3” 0 1 0 230844 CPVC VENT ADAPTOR 4” 0 0 1 230854 INTAKE ADAPTOR 4” 0 1 1 230841 VENT/INTAKE ADAPTOR GASKET N/A 1 0 0 230855 FLUE GAS SAMPLE CAP N/A 1 1 1 230823 30” STRAIGHT CPVC SECTION 3” 1 1 0 230824 30” STRAIGHT CPVC SECTION 4” 0 0 1 230813 90 DEG CPVC ELBOW 3” 1 1 0
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FIGURE 1.9a: LOCATION OF VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE FIGURE 1.9b: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS FIGURE 1.9c: POSITIONING VENT TERMINAL UNDER OVERHANGS 8 9
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FIGURE 1.10: SNORKEL TERMINAL CONFIGURATION FIGURE 1.11.a FIGURE 1.11.b FIGURE 1.11.c FIGURE 1.11: EXPANSION LOOPS 10 11
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TABLE 1.12: SUMMARY OF VERTICAL VENTING OPTIONS VENT OPTION # 5 6 7 8 CLASSIFICATION USED IN THIS VERTICAL VERTICAL VERTICAL VERTICAL MANUAL TWIN PIPE TWIN PIPE TWIN PIPE TWIN PIPE ILLUSTRATED IN FIGURE 1.14 1.15 1.16 1.16 VENT PIPE PENETRATION ROOF ROOF ROOF ROOF THROUGH STRUCTURE AIR INTAKE PIPE PENETRATION ROOF ROOF ROOF ROOF THROUGH STRUCTURE 3” 3” VENT PIPE SIZE 3” 4” AIR INTAKE PIPE SIZE 3” 3” 4” 4” BWC070 98ft 98ft BWC090 98ft 98ft BWC120 98ft 98ft BWC151 98ft 98ft BWC150 51ft BWC2
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FIGURE 1.13: WALL PENETRATION CLEARANCES FOR PVC VENT PIPE FIGURE 1.14: VERTICAL CPVC/PVC VENTING, BWC070/090/120/151 (VENT OPTION 5) 12 13
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FIGURE 1.15: VERTICAL CPVC/PVC VENTING, BWC070/090/120/151 (VENT OPTION 6) FIGURE 1.16: VERTICAL CPVC/PVC VENTING, BWC150/225 (VENT OPTIONS 7 & 8) 12 13
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B. Assembly of CPVC/PVC Vent Systems 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. • All CPVC vent components (supplied with the boiler) must be used for near boiler vent piping before transitioning to Schedule 40 PVC (ASTM 2665) components for the remainder of the system. • The use of cellular core PVC (ASTM F891) is prohibited. • The use of CPVC is required where venting passes t
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FIGURE 1.17: INSTALLATION OF VENT/INTAKE ADAPTOR (BWC070/090/120/151) FIGURE 1.18: INSTALLATION OF VENT AND INTAKE ADAPTORS (BWC150/225) 14 15
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FIGURE 1.19: INSTALLATION OF STANDARD HORIZONTAL TERMINALS 2. Assemble the vent system, starting at the boiler: a. The CPVC elbow and the 30” straight section of CPVC provided with the kit must be used before transitioning to PVC. If necessary, the 30” straight section of CPVC may be cut at any location and the CPVC elbow inserted between the two resulting segments. b. When cutting CPVC or PVC pipe, use a miter saw or a saw designed to cut PVC pipe. Use a miter box or other method to cut pi
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FIGURE 1.20: INSTALLATION OF STANDARD VERTICAL TERMINALS 4. Installation of Standard Terminals: Horizontal (Tee Terminals): a. When using Tee terminals, the inside edge of the run of the Tee must be between 6 and 24” from the wall. b. The run of the Tee must be vertical. (Figure 1.19). c. If desired, the Tees can be attached to the end of the vent and/or intake pipes with field supplied stainless steel screws so that they can be later removed for cleaning and inspection. If this is done, dri
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5. Installation of Optional Crown # 230873 concentric vent terminal - This terminal may be used for either horizontal or vertical venting. Do not attempt to use this terminal on a BWC150 or BWC225. All CPVC supplied with the vent kit must be used prior to connection of the vent system to this terminal. If the vent system is too short to permit this, do not use this terminal: Horizontal Installations- a. Cement the 4” diameter section of PVC pipe supplied with this kit to the Wye fitting usin
