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Crown Boiler BWC120 manual

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Table of contents for the manual

  • Page 1

    BWC070, BWC090, BWC120 Installation Manual Supplement June 12 th , 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)[...]

  • Page 2

    VII V enting W ARNING F AILURE T O VENT THIS BOILER IN ACCORDANCE WITH THESE INSTRUCTIONS COULD CAUSE FLUE GAS T O ENTER THE BUILDING RESUL TING IN SEVERE PROPER TY DAMAGE, PERSONAL INJUR Y , OR DEA TH: * Do not attempt to vent this boiler with galvanized, PVC, or any other vent components not listed in T able 7.4. * Do not attempt to mix component[...]

  • Page 3

    12 2) Maximum V ent and Air Intake Lengths - The maximum length of the vent air intake piping depends upon the vent option selected and the boiler size. See T able 7.1 or 7.9 for the maximum vent length. In horizontal vent systems, the lengths shown in T able 7.1 are in addition to the first standard elbow on top of the boiler . For vertical vent [...]

  • Page 4

    13 T ABLE 7.1: SUMMAR Y OF HORIZONT AL VENTING OPTIONS VENT OPTION # 1 2 3 CLASSIFICA TION USED IN THIS MANUAL HORIZONT AL CONCENTRIC HORIZONT AL TWIN PIPE HORIZONT AL CONCENTRIC ILLUSTRA TED IN FIGURE 7.2 7.3 7.2 VENT PIPE PENETRA TION THROUGH STRUCTURE W ALL W ALL W ALL AIR INT AKE PIPE PENETRA TION THROUGH STRUCTURE W ALL W ALL W ALL VENT PIPE S[...]

  • Page 5

    14 FIGURE 7.2: HORIZONT AL CONCENTRIC VENTING (VENT OPTION 1,3) FIGURE 7.3: HORIZONT AL TWIN PIPE VENTING (VENT OPTION 2)[...]

  • Page 6

    15 T ABLE 7.4a: CROWN CONCENTRIC 60/100 VENT COMPONENTS (VENT OPTION 1) CROWN PN DESCRIPTION SIZE USED ON VENT OPTION # COMMENTS 230521 80/125 x 60/100mm REDUCING ELBOW 80/125 x 60/100mm 1 INCLUDED WITH ST ANDARD BOILER 230520 TERMINAL SECTION 60/100mm 1 INCLUDED WITH ST ANDARD BOILER 230522 W ALL GROMMET 60/100mm 1 INCLUDED WITH ST ANDARD BOILER 2[...]

  • Page 7

    6) Permitted T erminals for V ertical V enting - • V ent Option 5 - A straight termination is installed in the end of the vent pipe. V ent manufacturer part numbers for these screens are shown in T able 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. • V ent Opti[...]

  • Page 8

    FIGURE 7.6a: LOCA TION OF VENT TERMINAL RELA TIVE TO WINDOWS, DOORS, GRADE FIGURE 7.6b: LOCA TION OF VENT TERMINAL RELA TIVE TO METERS AND FORCED AIR INLETS FIGURE 7.6c: POSITIONING VENT TERMINAL UNDER OVERHANGS 17[...]

  • Page 9

    18 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 - V ertical and horizontal sections of pipe must be properly supported: • [...]

  • Page 10

    19 T ABLE 7.9: SUMMAR Y OF VER TICAL VENTING OPTIONS VENT OPTION # 5 6 CLASSIFICA TION USED IN THIS MANUAL VER TICAL TWIN PIPE VER TICAL CONCENTRIC ILLUSTRA TED IN FIGURE 7.10 7.1 1 VENT PIPE PENETRA TION THROUGH STRUCTURE ROOF ROOF AIR INT AKE PIPE STRUCTURE THROUGH STRUCTURE ROOF ROOF VENT PIPE SIZE 3” 80/125 mm CONCENTRIC AIR INT AKE PIPE SIZE[...]

  • Page 11

    20 FIGURE 7.10: VER TICAL TWIN PIPE VENT SYSTEM (VENT OPTION 5) FIGURE 7.1 1: VER TICAL CONCENTRIC VENT SYSTEM (VENT OPTION 6)[...]

  • Page 12

    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[...]

  • Page 13

    22 C. Assembly of Crown 60/100mm Concentric V enting (IMPOR T ANT - Skip to Section D for 80/125mm Concentric V ent Assembly) W ARNING Failure to follow the instructions could r esult in flue gas leakage into the combustion air or indoor air , resulting in unsafe or unr eliable operation. • Do not lubricate concentric gaskets with anything other[...]

  • Page 14

    FIGURE 7.21: DIMENSION “L” 23 FIGURE 7.20: INST ALLA TION OF REDUCING ELBOW ON CONCENTRIC BOILER COLLAR[...]

  • Page 15

    24 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 s[...]

  • Page 16

    FIGURE 7.25: A TT ACHING 60/100mm TERMINAL SECTION 25 FIGURE 7.24: PREP ARING 60/100mm TERMINAL SECTION FOR INST ALLA TION IN THE W ALL[...]

  • Page 17

    D. Assembly of Crown 80/125mm Concentric V enting (IMPOR T ANT - See Section C for 60/100mm Concentric V ent Assembly) W ARNING Failure to follow the instructions could r esult in flue gas leakage into the combustion air or indoor air , resulting in unsafe or unr eliable operation. • Do not lubricate concentric gaskets with anything other than w[...]

  • Page 18

    T o 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 t[...]

  • Page 19

    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 ab[...]

  • Page 20

    4) 80/125mm Horizontal T erminal 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 len[...]

  • Page 21

    FIGURE 7.33c: CUTTING INNER PIPE OF 80/125mm HORIZONT AL TERMINAL FIGURE 7.33d: COMPLETING 80/125mm HORIZONT AL TERMINAL INST ALLA TION 30[...]

  • Page 22

    5) Snorkel T erminal Installation - The Snorkel Kit (PN 230540) consists of the following (Also see Figure 7.34): Key # Part # Description 1 230541 Support Elbow 2 230542 Lower W all Bracket 3 230543 Air Intake Section 4 230544 W all Bracket 5 230545 T erminal Elbow 6 230546 Exhaust T erminal 7 230527 Standard Elbow 8 230547 W all Penetration Secti[...]

  • Page 23

    d) Complete the vent system inside the structure. The support elbow sits on the M10 x 35 screw as shown in Figure 7.34. Cut the W all Penetration Section to the length required to connect the interior vent system to the Support Elbow following the instructions on Page 26. e) Remove the Support Elbow from the Lower Support Bracket and attach it to t[...]

  • Page 24

    FIGURE 7.35b: CUTTING VER TICAL TERMINAL FIGURE 7.35c: COMPLETING VER TICAL TERMINAL INST ALLA TION 33[...]

  • Page 25

    FIGURE 7.36: CHIMNEY CHASE INST ALLA TION 7) Chimney Chase Installation - A vertical 80/125mm vent system can be installed in an unused masonry chimney . This installation is similar to other vertical installations with the following exceptions (Also see Figure 7.36): a) The chimney chase elbow kit (PN230530) is used at the base of the chimney . Th[...]

  • Page 26

    CAUTION V ent systems made by Heat Fab, Protech, Z-Flex, and Metal-Fab 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 . ?[...]

  • Page 27

    36 3) Assembly of Metal-Fab Corr/Guard V ent System: a) Corr/Guard General Notes: • Do not cut Corr/Guard vent components. • Refer to Corr/Guard installation instructions for proper methods of support. • Orient Corr/Guard components so that the males ends of all fittings point in the direction of the boiler . b) Start assembly of the vent sy[...]