Crown Boiler BWC120 User Manual

BWC070, BWC090, BWC120  
Installation Manual Supplement  
June 12th, 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 vent applications.  
3) An 80/125mm concentric snorkel kit is now offered.  
4) Metal-Fab “Corr/Guard” may now be used for stainless steel vent applications.  
Refer to the installation manual supplied with the boiler for important warnings and  
other information not covered in this supplement.  
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 allowable vent length must be reduced by the amount shown in Table 7.8 for each  
additional elbow used. Termination fittings are never counted, although the length of the concentric terminal section  
is counted.  
Example:  
A 60/100mm concentric vent system is planned for a horizontally vented BWC120 which has the following  
components:  
80/125 x 60/100mm Reducing Elbow (supplied with the boiler)  
5ft Straight Pipe  
90 elbow  
1-1/2ft Straight Pipe  
45Elbow  
Uncut Terminal Section (supplied with the boiler)  
The Vent Option #1 column in Table 7.1 describes a horizontal direct vent system using 60/100mm concentric vent  
pipe. From this column, we see that a BWC120 may have a vent length of up to 18ft. The 90 degree reducing elbow  
is not considered. The length of the terminal section (not including the plastic terminal itself) is approximately 22  
1/2” (1.9ft) installed. From Table 7.8, we see that the equivalent length of the 60/100mm elbow is 4.5ft and that the  
equivalent length of the 45 degree elbow is 4ft. The total equivalent length of the planned venting system is therefore:  
5ft (Straight ) + 4.5ft (90 Elbow) + 1.5ft (Straight ) + 4 ft (45 Elbow) + 1.9ft (Uncut Terminal Section) = 16.9ft.  
Since Table 7.1 shows a maximum allowable vent length of 18ft, the planned vent system length is acceptable.  
3) Minimum Vent and Air Intake Lengths - Observe the minimum vent lengths shown in tables 7.1 and 7.9.  
4) Permitted Terminals for Horizontal Venting:  
Vent Option 1 - The 60/100mm concentric vent terminal is supplied with the boiler as part of the standard vent  
system.  
Vent Option 2 - The exhaust terminal is Crown PN 230511. The air intake fitting is a 90 degree elbow with a rodent  
screen supplied by the installer. 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 7.3.  
Vent Option 3 - Two terminals are permitted:  
a) 80/125mm Concentric Vent Terminal (Crown PN 230531)  
b) 80/125mm Snorkel Terminal (Crown PN 230540) . This terminal allows the vent system to exit the building  
close to grade and go up the exterior wall far enough to provide adequate clearance between the terminal itself  
and the snow line (Figure 7.7).  
5) Horizontal Vent and Air Intake Terminal Location - Observe the following limitations on the vent terminal location  
(also see Figures 7.6, 7.7). When locating a concentric terminal, observe the limitations outlined below for “vent  
terminals”.  
Vent terminals must be at least 1 foot from any door, window, or gravity inlet into the building.  
• For twin pipe terminals, maintain the correct clearance and orientation between the vent and air intake terminals.  
The vent and air intake terminals must be at the same height and their center lines must be between 12 and 36  
inches apart. Both terminals must be located on the same wall.  
• The bottom of all terminals must be at least 12” above the normal snow line. In no case should they be less than  
12” above grade level.  
• The bottom of the vent terminal must be at least 7 feet above a public walkway.  
• Do not install the vent terminal directly over windows or doors.  
• The bottom of the vent terminal must be at least 3 feet above any forced air inlet located within 10 feet.  
• A clearance of at least 4 feet horizontally must be maintained between the vent terminal and gas meters, electric  
meters, regulators, and relief equipment. Do not install vent terminal over this equipment.  
• Do not locate the vent terminal under decks or similar structures.  
• Top of vent terminal must be at least 5 feet below eves, soffits, or overhangs. Maximum depth of overhang is 3 ft.  
12  
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 boiler cannot be guaranteed if these terminals are subjected to winds in excess of 40 mph.  
• Air intake terminal must not terminate in areas that might contain combustion air contaminates, such as near  
swimming pools. See Section IV for more information on possible contaminates.  
TABLE 7.1: SUMMARY OF HORIZONTAL VENTING OPTIONS  
VENT OPTION #  
1
2
3
CLASSIFICATION USED IN THIS  
MANUAL  
HORIZONTAL  
CONCENTRIC  
HORIZONTAL  
TWIN PIPE  
HORIZONTAL  
CONCENTRIC  
ILLUSTRATED IN FIGURE  
7.2  
7.3  
7.2  
VENT PIPE PENETRATION  
THROUGH STRUCTURE  
WALL  
WALL  
WALL  
AIR INTAKE PIPE PENETRATION  
THROUGH STRUCTURE  
WALL  
WALL  
WALL  
VENT PIPE SIZE  
AIR INTAKE PIPE SIZE  
BWC070  
3”  
3”  
60/100 mm  
CONCENTRIC  
80/125 mm  
CONCENTRIC  
32ft  
32ft  
18ft  
32ft  
32ft  
18ft  
10in  
10in  
10in  
10in  
10in  
10in  
55ft  
55ft  
55ft  
55ft  
55ft  
55ft  
2ft  
55ft  
55ft  
55ft  
55ft  
55ft  
55ft  
2ft  
BWC090  
BWC120  
BWC070  
BWC090  
BWC120  
BWC070  
BWC090  
2ft  
2ft  
BWC120  
2ft  
2ft  
BWC070  
2ft  
2ft  
BWC090  
2ft  
2ft  
BWC120  
2ft  
2ft  
CROWN  
#230511  
Crown 230531  
CONCENTRIC  
or 230540  
VENT TERMINAL  
60/100 mm  
CONCENTRIC  
AIR INTAKE TERMINAL  
3” 90 ELBOW  
SNORKEL  
APPROVED  
STAINLESS  
STEEL VENT  
SYSTEM  
SHOWN IN  
TABLE 7.5  
CROWN  
60/100mm  
VENT  
COMPONENTS  
SHOWN IN  
TABLE 7.4a  
(Note #1)  
CROWN  
80/125mm VENT  
COMPONENTS  
SHOWN IN  
VENT MATERIAL  
TABLE 7.4b  
GALVANIZED  
OR PVC  
AIR INTAKE MATERIAL  
Note #1: In Vent Option #1, the 80/125mm concentric straight section (PN 230515) shown in Table 7.4a may be used between the  
boiler and the first 80/125 x 60/100 reducing elbow. If this is done, the overall maximum vent length is still restricted to that shown for  
Vent Option #1 in Table 7.1 above.  
13  
FIGURE 7.2: HORIZONTAL CONCENTRIC VENTING  
(VENT OPTION 1,3)  
FIGURE 7.3: HORIZONTAL TWIN PIPE VENTING (VENT OPTION 2)  
14  
TABLE 7.4a: CROWN CONCENTRIC 60/100 VENT COMPONENTS  
(VENT OPTION 1)  
USED ON  
CROWN PN  
230521  
DESCRIPTION  
SIZE  
VENT  
OPTION #  
COMMENTS  
80/125 x 60/100mm REDUCING  
ELBOW  
80/125 x  
60/100mm  
1
INCLUDED WITH STANDARD BOILER  
230520  
230522  
230505  
230504  
230506  
230507  
230508  
230515  
TERMINAL SECTION  
WALL GROMMET  
39” STRAIGHT  
60/100mm  
60/100mm  
60/100mm  
60/100mm  
60/100mm  
60/100mm  
60/100mm  
80/125mm  
1
1
1
1
1
1
1
1
INCLUDED WITH STANDARD BOILER  
INCLUDED WITH STANDARD BOILER  
OPTIONAL - MAY NOT BE CUT  
OPTIONAL - MAY NOT BE CUT  
OPTIONAL - CAN BE CUT  
OPTIONAL  
78” STRAIGHT  
19 1/2” STRAIGHT  
90 DEGREE ELBOW  
45 DEGREE ELBOW  
39” STRAIGHT  
OPTIONAL  
OPTIONAL - CAN BE CUT (Note #1)  
Note #1: On 60/100mm vent systems, this may only be used between the boiler and the first 80/125 x 60/100 Reducing elbow (see text).  
TABLE 7.4b: CROWN CONCENTRIC 80/125 VENT COMPONENTS  
(VENT OPTIONS 3,6)  
USED ON  
CROWN PN  
DESCRIPTION  
SIZE  
VENT  
COMMENTS  
OPTION #  
230527  
230528  
230526  
230517  
230515  
230518  
230519  
230525  
230531  
230540  
230532  
230533  
230535  
90 DEGREE EL (STANDARD)  
90 DEGREE EL (SWEEP)  
45 DEGREE EL  
80/125mm  
80/125mm  
80/125mm  
80/125mm  
80/125mm  
80/125mm  
80/125mm  
80/125mm  
80/125mm  
80/125mm  
80/125mm  
80/125mm  
80/125mm  
3,6  
3,6  
3,6  
3,6  
3,6  
3,6  
3,6  
3,6  
3
19 1/2” STRAIGHT  
CAN BE CUT  
CAN BE CUT  
39” STRAIGHT  
39” STRAIGHT  
MAY NOT BE CUT  
78” STRAIGHT  
MAY NOT BE CUT  
TELESCOPING STRAIGHT  
HORIZONTAL TERMINAL  
SNORKEL KIT  
ADJUSTABLE FROM 12-1/2” TO 16-1/2  
3
(NOTE #1)  
(NOTE #2)  
VERTICAL TERMINAL  
FLAT ROOF FLASHING  
SLOPED ROOF FLASHING  
6
6
6
(NOTE #3)  
(NOTE #4)  
SUPPORT ELBOW WITH  
CHIMNEY CHASE BRACKET  
230530  
230536  
80/125mm  
80/125mm  
6
SUPPORT BAND  
3,6  
Table 7.4b Notes:  
1) Snorkel kit includes parts needed to offset terminal on exterior wall by up to 46”.  
2) Vertical terminal can be used with either of the roof flashings listed beneath it.  
3) Sloped roof flashing suitable for roof angles between 25 and 45 degrees.  
4) Used at base of vertical run inside unused masonry chimney.  
15  
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 limitations on the location of all vertical vent  
terminals (see Figures 7.10, 7.11):  
• The top of the vent pipe must be at least 2 feet above any object located within 10 feet.  
• For Vent Option #5, the vertical distance between top of the 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. The terminal used in Vent Option #6 has a fixed distance above the storm collar of 19”. If a greater distance is  
needed to provide the clearance above the snow line, build a chase on the roof and mount the vertical terminal on top of  
the chase.  
• For Vent Option #5, the air intake terminal must be located on the roof and must be no further than 24” horizontally from  
the exhaust pipe.  
8) Wall thimbles – Wall thimbles are required where single wall vent pipe passes through combustible walls with less than  
the required clearance shown in Table 4.2 or as required by local codes. Stainless vent manufacturer’s wall thimble part  
numbers are shown in Table 7.5. Note that concentric vent has a “zero” clearance to combustibles and therefore does not  
require the use of wall thimbles.  
TABLE 7.5: PERMISSIBLE STAINLESS STEEL VENT SYSTEMS  
AND PRINCIPLE VENT COMPONENTS  
(VENT OPTIONS 2, 5)  
VENT  
SYSTEM  
MANUFACTURER  
SIZE  
COMPONENT  
PART NUMBER  
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
BOILER COLLAR  
CROWN 230510  
HEAT FAB 7393, 7393GCS, 5391CI  
CROWN 230511  
HEAT FAB 9392  
CROWN 230510  
FSWT3  
SAF-T  
VENT  
EZ SEAL  
WALL THIMBLE  
HEAT FAB  
HORIZONTAL TERMINAL  
VERTICAL TERMINAL  
BOILER COLLAR  
PROTECH  
SYSTEMS  
INC.  
WALL THIMBLE  
FASNSEAL  
HORIZONTAL TERMINAL  
VERTICAL TERMINAL  
BOILER COLLAR  
CROWN 230511  
FSBS3  
CROWN 230510  
2SVSWTEF03  
SVE  
SERIES III  
(“Z-VENT  
III”)  
WALL THIMBLE  
Z-FLEX  
HORIZONTAL TERMINAL  
VERTICAL TERMINAL  
BOILER COLLAR  
CROWN 230511  
24SVSTPF03  
CROWN 230510  
CGSWWPK(3”)  
CROWN 230511  
CGSWHTM(3”)  
WALL THIMBLE  
CORR/  
GUARD  
METAL-FAB  
HORIZONTAL TERMINAL  
VERTICAL TERMINAL  
NOTES:  
1) See vent system manufacturer’s literature for other part numbers that are required such as straight pipe, elbows, firestops and vent supports.  
2) Crown 230510 collar replaces factory-mounted concentric collar (Figure 7.16).  
16  
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  
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 (Figure 7.36) need only be supported at the  
terminal and at the base of the run.  
• Support stainless steel venting as called for by the vent manufacturer’s instructions.  
FIGURE 7.7: SNORKEL TERMINAL CONFIGURATION  
18  
TABLE 7.8: VENT/ AIR INTAKE FITTING EQUIVALENT LENGTH  
VENT FITTING  
60/100mm 90° CONCENTRIC ELBOW  
EQUIVALENT LENGTH (ft)  
4.5  
60/100mm 45° CONCENTRIC ELBOW  
80/125mm 90° CONCENTRIC ELBOW  
80/125mm 90° SWEEP CONCENTRIC ELBOW  
80/125mm 45° CONCENTRIC ELBOW  
80/125mm 90° CONCENTRIC SUPPORT ELBOW  
3” SINGLE WALL 90° ELBOW  
4.0  
8.5  
5.5  
3.0  
8.5  
5.5  
4.0  
3” SINGLE WALL 45° ELBOW  
TABLE 7.9: SUMMARY OF VERTICAL VENTING OPTIONS  
VENT OPTION #  
5
6
CLASSIFICATION USED IN THIS  
MANUAL  
VERTICAL  
TWIN PIPE  
VERTICAL  
CONCENTRIC  
ILLUSTRATED IN FIGURE  
7.10  
7.11  
VENT PIPE PENETRATION  
THROUGH STRUCTURE  
ROOF  
ROOF  
AIR INTAKE PIPE STRUCTURE  
THROUGH STRUCTURE  
ROOF  
ROOF  
VENT PIPE SIZE  
AIR INTAKE PIPE SIZE  
BWC070  
3”  
3”  
80/125 mm CONCENTRIC  
49.5ft  
49.5ft  
49.5ft  
49.5ft  
49.5ft  
49.5ft  
2ft  
49.5ft  
49.5ft  
49.5ft  
49.5ft  
49.5ft  
49.5ft  
2ft  
BWC090  
BWC120  
BWC070  
BWC090  
BWC120  
BWC070  
BWC090  
2ft  
2ft  
BWC120  
2ft  
2ft  
BWC070  
2ft  
2ft  
BWC090  
2ft  
2ft  
BWC120  
2ft  
2ft  
STRAIGHT TERMINAL  
BY VENT SYSTEM MFR.  
(TABLE 7.5)  
VENT TERMINAL  
CROWN #230532  
CONCENTRIC TERMINAL  
(TABLE 7.4b)  
3” 180° ELBOW  
(FIGURE 7.10)  
AIR INTAKE TERMINAL  
APPROVED STAINLESS  
STEEL VENT SYSTEM  
CROWN 80/125 mm VENT  
COMPONENTS SHOWN IN  
TABLE 7.4b  
VENT MATERIAL  
AIR INTAKE MATERIAL  
GALVANIZED OR PVC  
19  
FIGURE 7.10: VERTICAL TWIN PIPE VENT SYSTEM (VENT OPTION 5)  
FIGURE 7.11: VERTICAL CONCENTRIC VENT SYSTEM (VENT OPTION 6)  
20  
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 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 deficiencies 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 fireplace 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 flame 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, fireplace 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 re-sizing any portion of the common venting system, the  
common venting system should be re sized to approach the minimum size as determined using the appropriate  
tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1.  
WARNING  
NEVER COMMON VENT A BWC BOILER WITH OTHER APPLIANCES.  
21  
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 for proper insertion.  
• Do not attempt to try to mix this concentric pipe with other venting systems.  
1) Concentric vent components supplied with the boiler are packed inside the boiler carton and include the following:  
a) 80/125 x 60/100mm reducing elbow (Crown PN 230521).  
b) 60/100mm terminal section (straight section with a terminal and overall length of 27 3/4” (Crown PN 230520).  
c) Two (2) Rubber wall grommets (Crown PN 230522).  
2) Unless the 80/125 straight riser (PN 230515) is used, start by attaching the reducing elbow to the boiler collar. To  
do so, remove the clamp from the large end of the reducing elbow and set aside. Apply a small amount of water to  
the brown gasket on the boiler collar. Push the elbow onto the boiler collar until the bead on the elbow contacts the  
top edge of the collar (Figure 7.20).  
3) Reinstall the clamp removed in Step (2) so that the elbow is secured to the boiler collar.  
4) If no additional sections of concentric pipe are required, attach the terminal section to the elbow. In most cases, it  
will need to be cut before doing so. Use the following procedure to cut the pipe:  
a) Measure distance “L” from the outside surface of the exterior wall to the end of the elbow as shown in Figure  
7.21.  
b) Add 2-1/8” to distance “L”. Carefully mark this length on the pipe as shown in Figure 7.22.  
c) Press in the two tabs holding the plastic terminal in the terminal section (Figure 7.22). Carefully pull out the  
terminal and the inner pipe.  
d) Cut the outer pipe only at the point marked in Step (b) using aviation shears, a hacksaw, or an abrasive wheel  
cutter. Be careful to cut the pipe square. De burr the cut end with a file or emery cloth.  
e) Cut the plastic inner pipe so that it will protrude 3/8” beyond the outer pipe when reinstalled in the terminal  
section (Figure 7.23). Use a fine tooth hacksaw or a PVC saw to cut the plastic pipe and be careful to cut the pipe  
square. De burr the cut edge of the plastic pipe with a file, razor blade, or fine sandpaper.  
f) Reinstall the inner pipe in the terminal section. Slip the outside wall grommet over the terminal section and  
position so that it covers the joint between the outer pipe and the terminal (Figure 7.24).  
g) Make a mark on the terminal section 1” from the cut end of the outer pipe as shown in Figure 7.24.  
h) Pass the terminal section through the wall from the outside. Push the remaining wall grommet over the terminal  
section on the inside of the wall. Push the terminal section into the elbow until the mark made in Step (g) is no  
longer visible. If necessary, the brown gasket in the inner pipe may be lubricated with a few drops of water.  
i) The terminal section must be attached to the elbow with a single #10 x 1/2” sheet metal screw ( not supplied) at  
the top of the elbow. Drill a 1/8” hole in the location shown in Figure 7.25. Use a short drill bit or a drill stop  
to ensure that the drill bit does not penetrate the pipe by more than 3/8”. Install a #10 x 1/2” screw in this  
hole. Do not use a screw longer than 1/2” long.  
j) If not already done, make sure that both wall grommets are firmly against the interior and exterior wall surfaces.  
Seal any cracks or other openings near the terminal through which exhaust could enter the building.  
5) If additional pieces of pipe are used, install them starting at the boiler elbow. Support each section of straight pipe  
at its female end.  
22  
FIGURE 7.20: INSTALLATION OF REDUCING ELBOW ON CONCENTRIC BOILER COLLAR  
FIGURE 7.21: DIMENSION “L”  
23  
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”.  
7) The only straight pipe that can be cut is the terminal section, the 19-1/2” section (Crown PN 230506) and the 80/125  
straight riser (PN230515). To cut this pipe:  
a) Cut pipe from the male end. After marking the desired length of the outer pipe, remove the plastic inner pipe by pulling  
it out from the female end.  
b) Cut the outer pipe only at the point marked in Step (b) using aviation shears, a hacksaw, or an abrasive wheel cutter. Be  
careful to cut the pipe square. De burr the cut end with a file or emery cloth.  
c) Cut the plastic inner pipe so that it will protrude 3/8” beyond the outer pipe when reinstalled in the outer pipe. Use a  
fine tooth hacksaw or a PVC saw to cut the plastic pipe and be careful to cut the pipe square. De burr the cut edge of the  
plastic pipe with a file, razor blade, or fine sandpaper.  
d) Reinstall the inner pipe.  
8) Install the terminal as outlined in Step (4) above. Dimension “L” described in Step 4 is the distance from the exterior sur-  
face of the wall to the end of the last piece of pipe inside the building.  
FIGURE 7.22: CUTTING OUTER PIPE  
FIGURE 7.23: CUTTING INNER PIPE  
24  
FIGURE 7.24: PREPARING 60/100mm TERMINAL SECTION FOR INSTALLATION IN THE WALL  
FIGURE 7.25: ATTACHING 60/100mm TERMINAL SECTION  
25  
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 proper insertion.  
• Do not attempt to try to mix this concentric pipe with other venting systems.  
1) The 60/100mm terminal section and concentric reducing elbow supplied with the boiler are not used in 80/125mm  
vent systems. The components listed in Table 7.4b are required for 80/125mm installations and are not supplied  
with the boiler. Before starting assembly of an 80/125mm vent system, make sure that the planned installation is in  
accordance with the “Vent System Design” section of this manual and that all required 80/125mm vent components  
are on hand. These components are available through Crown distributors.  
2) Cutting Straight Pipe - The following straight pipe sections may be cut:  
Part #  
Description  
230517  
230515  
19 1/2” Straight  
39” Straight  
These sections have a plain male end (without beads - see Figure 7.30a). They are always cut from the male end.  
Sections not shown on the above list may not be cut. These sections have beads on the male end (Figure 7.30b).  
FIGURE 7.30a: CUTTABLE STRAIGHT SECTION  
FIGURE 7.30b: NON CUTTABLE STRAIGHT SECTION  
26  
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 careful to cut the pipe square. De burr the cut end with a file or emery cloth.  
d) Make an insertion mark 1” from the male end of the outer pipe.  
e) Cut the plastic inner pipe so that it will protrude 3/8” beyond the male end of the outer pipe when reinstalled  
in the outer pipe. Use a fine tooth hacksaw or a PVC saw to cut the plastic pipe and be careful to cut the pipe  
square. De burr the cut edge of the plastic pipe with a file, razor blade, or fine sandpaper.  
f) Reinstall the inner pipe.  
FIGURE 7.31: CUTTING STRAIGHT PIPE  
27  
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 held to the collar with 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” (Figure 7.32a).  
d) Use locking bands (provided with all fittings) to secure non-cuttable pipe, as well as fittings, to the boiler collar  
(Figure 7.32b).  
e) Use the same method to join all remaining vent components except for the terminal.  
FIGURE 7.32a: JOINING CUTTABLE PIPE  
FIGURE 7.32b: JOINING NON CUTTABLE PIPE  
28  
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 outer pipe only at the point marked in Step (c) using aviation shears, a hacksaw, or an abrasive  
wheel cutter. Be careful to cut the pipe square. De-burr the cut end with a file or emory cloth.  
f) Reinstall the plastic inner pipe in the terminal, making sure that the female end of this pipe is completely  
bottomed out over the aluminum male connection visible behind the air intake grill. Place a mark on the  
plastic inner pipe 3/8” beyond the end of the outer pipe (Figure 7.33c). Use a fine tooth hacksaw or a  
PVC saw to cut the plastic pipe and be careful to cut the pipe square (if necessary, the plastic pipe can be  
removed from the terminal again for cutting). De-burr the cut edge of the plastic pipe with a file, razor  
blade, or fine sandpaper.  
g) Make a mark on the terminal section 1” from the cut end of the outer pipe as shown in Figure 7.33c.  
h) Slip the terminal section through the wall from the outside. Pass the terminal through the inner wall plate  
and push into the last section of vent pipe until the mark made in Step (h) is not longer visible (Figure  
7.33d). Secure the terminal to the last piece of pipe with three #10 x 1/2” sheet metal screws. Drill a 1/8  
hole through both outer pipes to start these screws. 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”.  
i) Slip the outer wall plate over the terminal and secure to the wall (Figure 7.33d). Apply a 1/8” bead of  
weather resistant RTV over the joint between the outside wall plate and the terminal. Secure the other wall  
plate to the inside wall.  
FIGURE 7.33a: DIMENSION “L”, 80/125mm HORIZONTAL TERMINAL  
FIGURE 7.33b: CUTTING OUTER PIPE OF 80/125mm HORIZONTAL TERMINAL  
29  
FIGURE 7.33c: CUTTING INNER PIPE OF 80/125mm HORIZONTAL TERMINAL  
FIGURE 7.33d: COMPLETING 80/125mm HORIZONTAL TERMINAL INSTALLATION  
30  
5) Snorkel Terminal Installation - The Snorkel Kit (PN 230540) consists of the following (Also see Figure 7.34):  
Key # Part #  
Description  
1
2
3
4
5
6
7
8
230541  
230542  
230543  
230544  
230545  
230546  
230527  
230547  
Support Elbow  
IMPORTANT  
Lower Wall Bracket  
Air Intake Section  
Wall Bracket  
The Terminal Elbow and Wall  
Penetration Section included in the  
snorkel kit have gaskets in the female  
end of the outer pipe. These gaskets  
prevent infitration of rain water  
into the air intake section. Do not  
interchange with similar components  
shown in Table 7.4b.  
Terminal Elbow  
Exhaust Terminal  
Standard Elbow  
Wall Penetration Section  
*
230548  
Outer Joint Gasket (2 provided)  
a) Cut a 6” diameter hole through the exterior wall at the planned exit point of the vent. A minimum of 4” is needed  
between the center line of this hole and grade to install the lower wall bracket.  
b) Before mounting the lower wall bracket, loosen the M10 x 35 screw on this bracket. Adjust this bolt forward or  
backward so that its center is 6-7/16” from the wall (Figure 7.34) and tighten.  
c) Center the Lower Wall Bracket on the hole in the wall and mark the location of the four mounting screws on the  
wall. 5/16” mounting screws (not supplied) are recommended for mounting this bracket. Drill mounting holes  
and mount the bracket.  
FIGURE 7.34: INSTALLATION OF SNORKEL TERMINAL  
31  
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 Wall 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 the Wall Penetration Section. Slip this  
assembly through the Lower Support Bracket. Connect to the interior vent system.  
f) Slide an Outer Joint Gasket over the male end of the Air Intake Section with the tapered edge of the gasket pointing  
up. Attach the Air Intake Section to the Support Elbow. If necessary, the Air Intake Section can be shortened by  
cutting the male end as described on page 26. After attaching the Air Intake Section to the Support Elbow, slide the  
Outer Joint Gasket down over the joint between the two fittings to prevent rain infiltration.  
g) Attach the Wall bracket to the wall 0”-6” from the bottom edge of the intake bell (Figure 7.34). Use 1/4” screws (not  
provided) to mount this bracket.  
h) Slide the remaining Outer Joint Gasket over the male end of the Terminal Elbow. Attach the Terminal Elbow to the Air  
Intake Section, pointing it away from the wall. Secure the Terminal Elbow to the Air Intake section with a single #10  
x 1/2” sheet metal screw (Figure 7.34). 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”. Slide the Outer Joint Gasket down over the joint between the Terminal Elbow  
and the Air Intake Section to prevent rain infiltration.  
i) Attach the Exhaust Terminal to the Terminal Elbow (Figure 7.34).  
6) Vertical Terminal Installation - In addition to the vertical terminal, either a Flat Roof Flashing (PN 230533) or Sloped  
Roof Flashing (PN 230535) is required for this installation.  
a) Determine the center line of the terminal location on the roof. If the roof is flat, cut a 5-1/2” diameter hole for the  
terminal. If the roof is sloped, cut a hole large enough for the terminal to pass through the roof while remaining  
plumb. Caution: If the boiler is installed directly under the hole, cover it while cutting the hole to prevent saw  
dust and other debris from falling into the boiler.  
b) Install the roof flashing using standard practice for the roofing system on the structure.  
c) If not already done, assemble the venting system inside the building. The last section of pipe needs to be on the same  
center line as the terminal and within 19-1/4” of the top edge of the roof flashing (Figure 7.35a).  
d) Measure distance “H” from the top edge of the storm collar to the end of the last fitting as shown in Figure 7.35a.  
e) Add 1” to distance “H”. Carefully mark this length on the pipe as shown in Figure 7.35b.  
f) Cut the outer pipe only at the point marked in Step (e) using aviation shears, a hacksaw, or an abrasive wheel cutter.  
Be careful to cut the pipe square. De-burr the cut end with a file or emery cloth.  
g) Place a mark on the aluminum inner pipe 3/8” beyond the end of the outer pipe (Figure 7.35b). Use a fine tooth  
hacksaw to cut the aluminum pipe and be careful to cut the pipe square. De-burr the cut edge of the aluminum pipe  
with a file or emery cloth.  
h) Make a mark on the terminal section 1” from the cut end of the outer pipe as shown in Figure 7.35b.  
i) Slip the terminal section through the roof from the outside. Push into the last section of vent pipe until the mark  
made in Step (h) is not longer visible. Secure the terminal to the last piece of pipe with three #10 x 1/2” sheet metal  
screws. Drill a 1/8” hole through both outer pipes to start these screws. 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”.  
j) Secure the terminal section to the inside of the roof structure using the mounting bracket provided with the terminal  
(Figure 7.35c).  
FIGURE 7.35a: DIMENSION “H”  
32  
FIGURE 7.35b: CUTTING VERTICAL TERMINAL  
FIGURE 7.35c: COMPLETING VERTICAL TERMINAL INSTALLATION  
33  
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. This kit consists of a support elbow  
and a mounting bracket. Slip the elbow over the M10 x 35 screw in the support bracket. Determine the desired  
vertical location of the support elbow in the chimney and mark the location of the pin on the back of the support  
bracket on the back wall of the chimney. Drill a 7/16”dia x 2-1/2” deep hole at this location to support the back  
of the bracket. The front of the elbow mounting bracket is supported by the bottom of the opening into the  
chimney or by an installer supplied bracket.  
b) Construct a weather-tight flat roof to cover the top of the old chimney. Install the vertical terminal through this  
roof using the flat roof flashing.  
WARNING  
• Do not attempt to construct a vertical vent system inside a chimney that is used to vent a fireplace or other  
appliances.  
• Do not attempt to construct a vertical vent system inside a chimney flue adjacent to another flue used by a fireplace  
or other appliances.  
FIGURE 7.36: CHIMNEY CHASE INSTALLATION  
34  
E. Assembly of Stainless Steel Venting  
CAUTION  
Vent 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.  
• 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 de burred prior to 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. 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.  
2) Mounting Stainless steel vent collar -The use of stainless steel venting requires the stainless steel vent collar  
(Crown PN 230510) which replaces the 80/125mm concentric collar supplied with the boiler. To install the stainless  
steel vent collar:  
a) Remove the six #10 sheet metal screws which attach the 80/125mm collar to the boiler.  
b) Remove the collar from the boiler (this may be easier if a twisting motion is applied to the collar while  
removing it).  
c) Lubricate the brown gasket in the female end of the plastic vent stub (inside the boiler) with a few drops of  
water.  
d) Push the stainless steel vent collar onto the boiler with a slight twisting motion. Make sure that the stainless  
steel vent adaptor is inserted at least 1” into the boiler stub.  
e) Secure the collar flange to the top of the boiler with the sheet metal screws removed in Step (a)  
FIGURE 7.46: INSTALLATION OF STAINLESS STEEL VENT COLLAR  
35  
3) Assembly of Metal-Fab Corr/Guard Vent 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 system at the boiler. Remove the hose clamp shipped on the BWC vent collar. Bend  
the three hose clamp tabs on this collar outward slightly.  
c) Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler. Remove  
dirt, grease, and moisture from the surfaces to be sealed. Dry surfaces or allow to dry thoroughly.  
d) On the male end of the pipe, apply a ¼” wide bead of silicone approximately 1/2” from the end of the pipe (Fig  
7.47).  
e) Insert the male end of the pipe into the boiler vent collar until it bottoms out.  
f) Apply an additional bead of silicone over the outside of the joint and smooth out.  
g) Replace and tighten the clamp on the vent collar.  
h) Assemble remaining Corr/Guard components in accordance with the Corr/Guard installation instructions.  
i) Allow the silicone to cure per the silicone manufacturer’s instructions before operating the boiler.  
FIGURE 7.47: CORR/GUARD CONNECTION TO VENT COLLAR  
36  

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