Crown Boiler BWC150 manual

BWC Series Direct V ent Condensing Boilers INST ALLA TION 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 W ARNING : Improper installation, adjustment, alteration, service or maintenance can cause property da[...]

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1 T able of Contents A. V ent System Design 2 B. Assembly of CPVC/PVC Concentric V enting 14 C. Condensate T rap and Drain 20 D. Removing An Existing Boiler From Common Chimney 22 E. Special Requirements For Side-W all V ented Appliances In The Commonwealth of Massachusetts 23[...]

2 3 W ARNING Failure to vent this boiler in accordance with these instructions could cause ue gas to enter the building resulting in sever e property damage, personal injury , or death: Use of the BWC boiler with CPVC/PVC venting r equires a special vent kit available from Cr own • Boiler Company . Do not attempt to vent the boiler using eithe[...]

2 3 T ABLE 1.1: SUMMAR Y OF HORIZONT AL VENTING OPTIONS VENT OPTION # 1 2 3 4 CLASSIFICA TION USED IN THIS MANUAL HORIZONT AL TWIN PIPE HORIZONT AL TWIN PIPE HORIZONT AL TWIN PIPE HORIZONT AL TWIN PIPE ILLUSTRA TED IN FIGURE 1.2 1.3 1.4 1.4 VENT PIPE PENETRA TION THROUGH STRUCTURE W ALL W ALL W ALL W ALL AIR INT AKE PIPE PENETRA TION THROUGH STRUCT[...]

4 5 Approved vent components and materials - The adaptor kits listed in T able 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 [...]

4 5 FIGURE 1.2: HORIZONT AL CPVC/PVC VENTING, BWC070/090/120/151 (V ent Option #1) FIGURE 1.3: HORIZONT AL CPVC/PVC VENTING, BWC070/090/120/151 (V ent Option #2)[...]

6 7 Horizontal V ent and Air Intake T erminal Location 6. - 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”. V ent terminal must be at least 1 foot from any door , window , or gravity inlet into the building. ?[...]

6 7 T ABLE 1.5: CROWN CPVC/PVC VENTING COMPONENTS CROWN PN DESCRIPTION USED ON VENT OPTION # COMMENTS 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 compo[...]

8 9 T ABLE 1.6: CROWN CPVC/PVC VENT KIT CONTENTS CROWN PN DESCRIPTION SIZE QTY PER VENT KIT PN 230595 (BWC070/090/120/151) PN 230596 (BWC150) PN 230597 (BWC225) 230840 CPVC/PVC VENT/INT AKE ADAPTOR 3” 1 0 0 230843 CPVC VENT ADAPT OR 3” 0 1 0 230844 CPVC VENT ADAPT OR 4” 0 0 1 230854 INT AKE ADAPTOR 4” 0 1 1 230841 VENT/INT AKE ADAPT OR GASK[...]

8 9 FIGURE 1.9a: LOCA TION OF VENT TERMINAL RELA TIVE TO WINDOWS, DOORS, GRADE FIGURE 1.9b: LOCA TION OF VENT TERMINAL RELA TIVE TO METERS AND FORCED AIR INLETS FIGURE 1.9c: POSITIONING VENT TERMINAL UNDER OVERHANGS[...]

10 11 FIGURE 1.10: SNORKEL TERMINAL CONFIGURA TION FIGURE 1.1 1: EXP ANSION LOOPS FIGURE 1.1 1.b FIGURE 1.1 1.a FIGURE 1.1 1.c[...]

10 11 FIGURE 1.1 1: EXP ANSION LOOPS T ABLE 1.12: SUMMAR Y OF VER TICAL VENTING OPTIONS VENT OPTION # 5 6 7 8 CLASSIFICA TION USED IN THIS MANUAL VER TICAL TWIN PIPE VER TICAL TWIN PIPE VER TICAL TWIN PIPE VER TICAL TWIN PIPE ILLUSTRA TED IN FIGURE 1.14 1.15 1.16 1.16 VENT PIPE PENETRA TION THROUGH STRUCTURE ROOF ROOF ROOF ROOF AIR INT AKE PIPE PEN[...]

12 13 FIGURE 1.14: VER TICAL CPVC/PVC VENTING, BWC070/090/120/151 (VENT OPTION 5) FIGURE 1.13: W ALL PENETRA TION CLEARANCES FOR PVC VENT PIPE[...]

12 13 FIGURE 1.15: VER TICAL CPVC/PVC VENTING, BWC070/090/120/151 (VENT OPTION 6) FIGURE 1.16: VER TICAL CPVC/PVC VENTING, BWC150/225 (VENT OPTIONS 7 & 8)[...]

14 15 B. Assembly of CPVC/PVC V ent Systems W ARNING Failure to follow the instructions could result in ue 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 [...]

14 15 FIGURE 1.17: INST ALLA TION OF VENT/INT AKE ADAPTOR (BWC070/090/120/151) FIGURE 1.18: INST ALLA TION OF VENT AND INT AKE ADAPTORS (BWC150/225)[...]

16 17 Assemble the vent system, starting at the boiler: 2. The CPVC elbow and the 30” straight section of CPVC provided with the kit must be used before a. 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. When cutting CPVC or PVC pipe[...]

16 17 Installation of Standard T erminals: 4. Horizontal (T ee T erminals): When using T ee terminals, the inside edge of the run of the T ee must be between 6 and 24” from the wall. a. The run of the T ee must be vertical. (Figure 1.19). b. If desired, the T ees can be attached to the end of the vent and/or intake pipes with eld supplied stai[...]

18 19 Installation of Optional Crown # 5. 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 permi[...]

18 19 FIGURE 1.21: INST ALLA TION OF OPTIONAL CONCENTRIC TERMINAL THROUGH SIDEW ALL FIGURE 1.22: INST ALLA TION OF OPTIONAL CONCENTRIC TERMINAL THROUGH ROOF[...]

20 21 C. Condensate T rap and Drain Line All condensate which forms in the boiler or vent system collects in the sump under the heat exchanger and leaves the boiler through the condensate trap. This trap allows condensate to drain from the sump while retaining ue gases in the boiler . On some BWC series boilers, this trap is supplied loose and m[...]

20 21 FIGURE 1.23 : CONDENSA TE PIPING ARRANGEMENT (BWC070/090/120/151) FIGURE 1.24: CONDENSA TE PIPING ARRANGEMENT FOR BWC150, 225[...]

22 23 D. Removing an Existing Boiler Fr om 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 la[...]

22 23 E: Special Requir ements For Side-W all V ented Appliances In The Commonwealth of Massachusetts IMPOR T ANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: 1. For direct-vent appliances, mechanical-vent heating appliances or domestic ho[...]

PN: 980034 Rev . 2 10/10 Manufacturer of Hydronic Heating Products P .O. Box 14818 3633 I. Street Philadelphia, P A 19134 T el: (215) 535-8900 • Fax: (215) 535-9736 • www .crownboiler .com[...]