Crown Boiler M600 User Manual

D E S I G N E D  
T O L E A D  
BWC Series  
BWC150/225 CONCENTRIC VENTING  
INSTALLATION INSTRUCTIONS  
These instructions must be afxed on or adjacent to the boiler.  
WARNING: Improper installation, adjustment, alteration,  
service or maintenance can cause property damage, injury,  
or loss of life. For assistance or additional information, con-  
Models:  
sult a qualied installer, service agency or the gas supplier.  
This boiler requires a special venting system. Read these  
instructions carefully before installing.  
BWC150  
BWC225  
Manufacturer of Hydronic Heating Products  
P.O. Box 14818 3633 I. Street  
Philadelphia, PA 19134  
Table of Contents  
A. Concentric Vent System Design  
2
9
B. Concentric Vent Adapter Kit Installation  
C. Assembly of Crown Concentric Venting and Condensate Drain  
11  
1
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 1.6.  
* 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 boiler.  
CAUTION  
Moisture and ice may form on the surfaces around the vent termination. To prevent deterioration, surfaces  
should be in good repair (sealed, painted, etc.).  
Concentric Venting For BWC150 and BWC225  
A. Concentric Vent System Design  
In addition to the vent options listed in the installation manual there are two other ways to vent this boiler:  
• Horizontal (“Side Wall”) Concentric Venting - Vent system exits the building through an outside wall.  
Concentric venting consists of a “pipe within a pipe”. Flue gas exits the building through the inner pipe and  
combustion air is drawn into the boiler through the space between the inner and outer pipe.  
Vertical Concentric Venting - Vent system exits the building through the roof. Concentric venting consists of a  
“pipe within a pipe”. Flue gas exits the building through the inner pipe and combustion air is drawn into the boiler  
through the space between the inner and outer pipe.  
These systems are considered “direct vent” because air for combustion is drawn directly from the outdoors into  
the boiler. A description of these venting options are shown in Tables 1.1 and 1.5. For clarity, the vent options  
are numbered 3 and 4 for the horizontal options and 8 and 9 for the vertical options. One of the vent option columns  
in Tables 1.1 or 1.5 must match the planned vent and air intake system exactly. In addition, observe the following  
guidelines:  
1) Approved concentric vent systems - The concentric vent system is optional for the BWC150 and BWC225 boilers.  
Each Crown concentric vent component consists of an inner pipe of polypropylene and the outer pipe of steel.  
Integral gaskets on each concentric tting provide a gas tight seal. Concentric pipe sizes are called out in terms  
of the inner and outer pipe nominal diameters in millimeters. For example, “80/125mm” pipe consists of a 80mm  
exhaust pipe inside a 125mm diameter outer pipe. A list of all Crown concentric vent components is shown in Table  
1.6. Use only one of the approved concentric vent systems shown in Table 1.6.  
A concentric vent adapter kit is required to use these boilers with concentric pipe. Part numbers for these kits are:  
BWC150  
BWC225  
P/N 230550  
P/N 230555  
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 1.1 or 1.5 for the maximum vent length. In horizontal vent systems,  
the lengths shown in Table 1.1 are in addition to the vent components which come with the Air Intake Box Kit and  
one standard radius elbow. For vertical vent systems, the maximum vertical vent lengths shown in Table 1.5 are in  
addition to the vent components which come with the Air Intake Box Kit and two standard radius elbows. If more  
elbows are desired, the maximum allowable vent length must be reduced by the amount shown in Table 1.4 for each  
additional elbow used. Termination ttings are never counted, although the length of the concentric terminal section  
is counted.  
2
Example:  
A 80/125mm concentric vent system is planned for a horizontally vented BWC150 which has the following  
components:  
Standard Radius 90° Elbow  
5ft Straight Pipe  
Standard Radius 90° Elbow  
1-1/2ft Straight Pipe  
45° Elbow  
Uncut Terminal Section  
The Vent Option #3 column in Table 1.1 describes a horizontal direct vent system using 80/125mm concentric vent  
pipe. From this column, we see that a BWC150 may have a vent length of up to 55ft The rst 90° standard radius  
elbow is not considered. The length of the terminal section (not including the terminal itself) is approximately 22.1”  
(1.84ft) installed. From Table 1.4, we see that the equivalent length of the 80/125mm 90° elbow is 8.5ft and that  
the equivalent length of the 45 degree elbow is 3.0ft. The total equivalent length of the planned venting system is  
therefore:  
5ft (Straight ) + 8.5ft (90 Elbow) + 1.5ft (Straight ) + 3.0ft (45 Elbow) + 1.84ft (Uncut Terminal Section) = 19.84ft.  
Since Table 1.1 shows a maximum allowable vent length of 55ft, the planned vent system length is acceptable.  
3) Minimum Vent and Air Intake Lengths - Observe the minimum vent lengths shown in Tables 1.1 and 1.5.  
4) Permitted Terminals for Horizontal Venting:  
Vent Option 3 - 80/125mm Concentric Vent Terminal (Crown PN 230531)  
Vent Option 4 - 100/150mm Concentric Vent Terminal (Crown PN 230569)  
5) Horizontal Vent and Air Intake Terminal Location - Observe the following limitations on the vent terminal location  
(also see Figure 1.3). 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.  
• The bottom of terminal must be at least 12” above the normal snow line. In no case should it 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, softs, or overhangs. Maximum depth of overhang is 3 ft.  
Vent terminal must be at least 6 feet from an inside corner.  
• Under certain conditions, water in the ue 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 ue 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.  
• Terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming  
pools. See Section IV in the installation manual for more information on possible contaminates.  
3
TABLE 1.1: SUMMARY OF HORIZONTAL VENTING OPTIONS  
VENT OPTION #  
3
4
CLASSIFICATION USED IN THIS  
MANUAL  
HORIZONTAL  
CONCENTRIC  
HORIZONTAL  
CONCENTRIC  
ILLUSTRATED IN FIGURE  
1.2  
1.2  
VENT PIPE PENETRATION  
THROUGH STRUCTURE  
WALL  
WALL  
AIR INTAKE PIPE PENETRATION  
THROUGH STRUCTURE  
WALL  
WALL  
VENT PIPE SIZE  
80/125 mm  
100/150 mm  
CONCENTRIC  
CONCENTRIC  
AIR INTAKE PIPE SIZE  
BWC150  
BWC225  
BWC150  
BWC225  
BWC150  
BWC225  
BWC150  
BWC225  
55  
55  
2
55  
55  
2
2
2
VENT TERMINAL  
Crown 230531  
CONCENTRIC  
TERMINAL  
Crown 230569  
CONCENTRIC  
TERMINAL  
AIR INTAKE TERMINAL  
CROWN  
80/125mm  
VENT  
CROWN  
100/150mm  
VENT  
VENT MATERIAL  
COMPONENTS  
SHOWN IN  
TABLE 1.6a  
COMPONENTS  
SHOWN IN  
TABLE 1.6b  
AIR INTAKE MATERIAL  
4
FIGURE 1.2: HORIZONTAL CONCENTRIC VENTING  
(VENT OPTION 3,4)  
6) Permitted Terminals for Vertical Venting -  
Vent Option 8 - Use Crown PN 230532 with the appropriate ashing (Table 1.6a)  
Vent Option 9 - Use Crown PN 230570 with the appropriate ashing (Table 1.6b)  
7) Vertical Vent Terminal Locations (Vent Options 8,9) - Observe the following limitations on the location of all vertical vent  
terminals (see Figure 1.7):  
• The top of the vent pipe must be at least 2 feet above any object located within 10 feet.  
• 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 Options 8 & 9 has a xed 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.  
8) Wall thimbles – Concentric vent has a “zero” clearance to combustibles and therefore does not require the use of wall  
thimbles.  
9) Pitch of Horizontal Piping - Pitch all horizontal piping 5/8” per foot so that any condensate which forms in the piping will  
run towards the boiler:  
10) Supporting Pipe - Support Crown concentric venting near the female end of each straight section of pipe.  
Exception: Vertical runs of concentric pipe in an unused chimney (Figure 1.14) need only be supported at the  
terminal and at the base of the run.  
5
FIGURE 1.3a: LOCATION OF VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE  
FIGURE 1.3b: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS  
FIGURE 1.3c: POSITIONING VENT TERMINAL UNDER OVERHANGS  
6
TABLE 1.4: VENT/ AIR INTAKE FITTING EQUIVALENT LENGTH  
VENT FITTING  
80/125mm 90° CONCENTRIC ELBOW  
EQUIVALENT LENGTH (ft)  
8.5  
80/125mm 90° SWEEP CONCENTRIC ELBOW  
80/125mm 45° CONCENTRIC ELBOW  
5.5  
3.0  
80/125mm 90° CONCENTRIC SUPPORT ELBOW  
100/150mm 90° SWEEP CONCENTRIC ELBOW  
100/150mm 45° CONCENTRIC ELBOW  
8.5  
8.0  
3.0  
100/150mm 90° CONCENTRIC SUPPORT ELBOW  
10.0  
TABLE 1.5: SUMMARY OF VERTICAL VENTING OPTIONS  
VENT OPTION #  
8
9
CLASSIFICATION USED IN THIS  
MANUAL  
VERTICAL  
CONCENTRIC  
VERTICAL  
CONCENTRIC  
ILLUSTRATED IN FIGURE  
1.7  
1.7  
VENT PIPE PENETRATION  
THROUGH STRUCTURE  
ROOF  
ROOF  
AIR INTAKE PIPE STRUCTURE  
THROUGH STRUCTURE  
ROOF  
ROOF  
VENT PIPE SIZE  
80/125 mm CONCENTRIC  
47  
100/150 mm CONCENTRIC  
AIR INTAKE PIPE SIZE  
BWC150  
BWC225  
BWC150  
BWC225  
BWC150  
BWC225  
BWC150  
BWC225  
45  
45  
2
47  
2
2
2
VENT TERMINAL  
CROWN #230532  
CONCENTRIC TERMINAL  
(TABLE 1.6a)  
CROWN #230570  
CONCENTRIC TERMINAL  
(TABLE 1.6b)  
AIR INTAKE TERMINAL  
CROWN 80/125 mm VENT  
COMPONENTS SHOWN IN COMPONENTS SHOWN IN  
CROWN 100/150 mm VENT  
VENT MATERIAL  
TABLE 1.6a  
TABLE 1.6b  
AIR INTAKE MATERIAL  
7
TABLE 1.6a: CROWN CONCENTRIC 80/125 VENT COMPONENTS  
(VENT OPTIONS 3,8)  
USED ON  
CROWN PN  
DESCRIPTION  
SIZE  
VENT  
COMMENTS  
OPTION #  
230527  
230528  
230526  
230517  
230515  
230518  
230519  
230525  
230531  
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  
3,8  
3,8  
3,8  
3,8  
3,8  
3,8  
3,8  
3,8  
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  
VERTICAL TERMINAL  
FLAT ROOF FLASHING  
SLOPED ROOF FLASHING  
ADJUSTABLE FROM 12-1/2” TO 16-1/2  
8
(NOTE #1)  
8
8
(NOTE #2)  
(NOTE #3)  
SUPPORT ELBOW WITH  
CHIMNEY CHASE BRACKET  
230530  
230536  
80/125mm  
80/125mm  
8
SUPPORT BAND  
3,8  
Table 1.6a Notes:  
1) Vertical terminal can be used with either of the roof ashings listed beneath it.  
2) Sloped roof ashing suitable for roof angles between 25 and 45 degrees.  
3) Used at base of vertical run inside unused masonry chimney.  
TABLE 1.6b: CROWN CONCENTRIC100/150 VENT COMPONENTS  
(VENT OPTIONS 8,9)  
USED ON  
CROWN PN  
DESCRIPTION  
SIZE  
VENT  
COMMENTS  
OPTION #  
230567  
230565  
230560  
230562  
230561  
230563  
230564  
230569  
230570  
230571  
230572  
90 DEGREE EL (SWEEP)  
45 DEGREE EL  
100/150mm  
100/150mm  
100/150mm  
100/150mm  
100/150mm  
100/150mm  
100/150mm  
100/150mm  
100/150mm  
100/150mm  
100/150mm  
4,9  
4,9  
4,9  
4,9  
4,9  
4,9  
4,9  
4
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  
VERTICAL TERMINAL  
FLAT ROOF FLASHING  
SLOPED ROOF FLASHING  
ADJUSTABLE FROM 12-1/2” TO 17-1/2  
9
(NOTE #1)  
9
9
(NOTE #2)  
(NOTE #3)  
SUPPORT ELBOW WITH  
CHIMNEY CHASE BRACKET  
230568  
230573  
100/150mm  
100/150mm  
9
SUPPORT BAND  
4,9  
Table 1.6b Notes:  
1) Vertical terminal can be used with either of the roof ashings listed beneath it.  
2) Sloped roof ashing suitable for roof angles between 25 and 45 degrees.  
3) Used at base of vertical run inside unused masonry chimney.  
8
FIGURE 1.7: VERTICAL CONCENTRIC VENT SYSTEM (VENT OPTION 6)  
B. Concentric Vent Adapter Kit Installation  
1) The Concentric Vent Adapter Kits include:  
P/N 230550 P/N 230555 Description  
(BWC150) (BWC225)  
240470  
240471  
90-054  
240472  
230539  
240552  
240550  
240480  
240481  
90-054  
240482  
230575  
240552  
240550  
Rubber Gasket  
Air Intake Box  
#10 x 3/4” Sheet Metal Screws  
Stainless Vent Adapter  
Concentric Condensate Collector  
Condensate Collector Adapter  
Tapped Condensate Trap Plug  
240560  
240555  
240557  
240560  
240555  
240557  
66”of 1/2” Clear PVC Tubing  
90° Hose Barb (2)  
1/2” Hose Clamps (2)  
Where the use of “silicone” is called for in the following instructions, use GE RTV106 for the vent adapters and  
any general-purpose silicone sealant such as GE RTV102 for the air inlet piping connection.  
a) Start assembly of the air intake box by rst removing the hose clamp shipped on the BWC vent collar.  
Bend the three hose clamp tabs on this collar inward slightly.  
b) Place the gasket over the vent collar and air intake collar as shown in Figure 1.8. The gasket should t  
snugly against the vent collar and air intake collar with no gaps.  
c) Bend the three hose clamp tabs on the vent collar outward slightly.  
d) Clean the exterior of the male end and interior of the female end of the stainless vent adapter 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.  
9
e) On the male end of the stainless vent adapter, apply a ¼” wide bead of silicone approximately 1/2” from  
the end of the pipe.  
f) Insert the male end of the stainless vent adapter into the boiler vent collar until it bottoms out.  
g) Apply an additional bead of silicone over the outside of the joint and smooth out.  
h) Replace and tighten the clamp on the vent collar.  
i) Remove one (BWC150) or two (BWC225) of the #10 sheel metal screws on the top of the rear jacket panel  
and place the air intake box over the vent and onto the boiler.  
j) Use the exposed holes to line up the air intake box and gasket.  
k) Insert the concentric condensate collector into the stainless vent adapter and the air intake box until the bead  
on the collector bottoms out on the air intake box collar. Turn the tting so that the threaded stub faces to the  
right.  
l) Square up the air intake box and the foam rubber gasket to the boiler jacket and loosely attach the box to the  
rear jacket panel with one of the previously removed #10 sheet metal screws.  
m) Drill a single 1/8” hole through one of the mounting holes on the opposite side of the air intake box and  
attach the box to the jacket with one of the #10 sheet metal screws. This will insure the rest of the mounting  
holes line up.  
n) Drill 1/8” holes in through the remaining mounting holes and attach the air intake box and gasket to the boiler  
jacket with the remaining #10 sheet metal screws.  
o) Apply pipe thread sealant tape (not supplied) to the 90° barbed hose ttings. Attach one to the condensate  
collector adapter and the other to the bottom of the tapped condensate trap plug. (Figures 1.8, 1.15)  
p) Attach the condensate collector adapter to the threaded portion of pipe sticking out the side of the concentric  
condensate collector so that the hose barb is facing down. Slide one end of the 1/2” clear plastic tubing over  
the hose barb and attach the hose clamp.  
q) Run the tubing down the right side panel and into the 1-3/8” knockout located on the lower right of the right  
side panel. Be sure to remove all burrs from the knockout to prevent the hose from being punctured.  
r) Remove the plug and black gasket ring from the bottom of the condensate trap located under the boiler.  
s) Reinstall the gasket ring onto the tapped condensate trap plug. Insert the tapped plug (which has the barbed  
hose tting attached to it) in the base of the trap in place of the original plug. Slide the other end of the clear  
plastic tubing over the hose barb and attach the hose clamp. (Figure 1.15)  
t) Allow the silicone to cure per the silicone manufacturer’s instructions before operating the boiler.  
FIGURE 1.8: CONCENTRIC VENT  
ADAPTER ASSEMBLY  
10  
C. Assembly of Crown Concentric Venting  
WARNING  
Failure to follow the instructions could result in ue 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 components listed in Table 1.6 are required for 80/125mm and 100/150mm installations and are not supplied  
with the BWC150/225 boilers. Before starting assembly of the vent system, make sure that the planned installation  
is in accordance with the “Vent System Design” section of this manual and that all required vent components are on  
hand. These components are available through Crown distributors.  
2) Cutting Straight Pipe - The following straight pipe sections may be cut:  
80/125 Part #  
100/150 Part #  
Description  
230517  
230515  
230560  
230562  
19 1/2” Straight  
39” Straight  
These sections have a plain male end (without beads - see Figure 1.9a). 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 1.9b).  
To cut the straight sections listed above refer to Figure 1.10 and the following instructions:  
FIGURE 1.9a: CUTTABLE STRAIGHT SECTION  
FIGURE 1.9b: NON CUTTABLE STRAIGHT SECTION  
11  
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 le 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 ne 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 le, razor blade, or ne sandpaper.  
f) Reinstall the inner pipe.  
3) Joining Pipe -  
FIGURE 1.10: CUTTING STRAIGHT PIPE  
12  
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 rst tting 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 ttings, the bead  
on the male pipe will bottom out on the collar (Figure 1.11b).  
c) The male end of cuttable ttings 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 1.11a).  
d) Use locking bands (provided with all ttings) to secure non-cuttable pipe, as well as ttings, to the boiler collar  
(Figure 1.11b).  
e) Use the same method to join all remaining vent components except for the terminal.  
4) Horizontal Terminal Installation  
FIGURE 1.11a: JOINING CUTTABLE PIPE  
FIGURE 1.11b: JOINING NON CUTTABLE PIPE  
13  
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 tting as shown in  
Figure 1.12a.  
c) Add 1-1/4” to distance “L”. Carefully mark this length on the pipe as shown in Figure 1.12b.  
d) Remove the aluminum 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 le or emory cloth.  
f) Reinstall the aluminum 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 aluminum inner pipe 3/8” beyond the end of the outer pipe (Figure 1.12c). Use a ne tooth  
hacksaw or hand shears to cut the aluminum pipe and be careful to cut the pipe square (if necessary, the  
aluminum pipe can be removed from the terminal again for cutting). De-burr the cut edge of the aluminum  
pipe with a le or ne sandpaper.  
g) Make a mark on the terminal section 1” from the cut end of the outer pipe as shown in Figure 1.12c.  
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  
1.12d). 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 1.12d). 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 1.12a: DIMENSION “L”, HORIZONTAL TERMINAL  
FIGURE 1.12b: CUTTING OUTER PIPE OF HORIZONTAL TERMINAL  
14  
FIGURE 1.12c: CUTTING INNER PIPE OF HORIZONTAL TERMINAL  
FIGURE 1.12d: COMPLETING HORIZONTAL TERMINAL INSTALLATION  
15  
6) Vertical Terminal Installation - In addition to the vertical terminal, either a Flat Roof Flashing (80/125 PN  
230533, 100/150 PN 230571) or Sloped Roof Flashing (80/125 PN 230535, 100/150 PN 230572) is required for  
this installation.  
a) Determine the center line of the terminal location on the roof. If the roof is at, cut a 5-1/2” diameter hole for  
the 80/125 terminal and a 6-1/2” diameter hole for the 100/150 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 ashing using standard practice for the roong 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” (80/125) or 28” (100/150) of the top edge of the roof ashing  
(Figure 1.13a).  
d) Measure distance “H” from the top edge of the storm collar to the end of the last tting as shown in Figure 1.13a.  
e) Add 1” to distance “H”. Carefully mark this length on the pipe as shown in Figure 1.13b.  
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 le or emery cloth.  
g) Place a mark on the aluminum inner pipe 3/8” beyond the end of the outer pipe (Figure 1.13b). Use a ne 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 le or emery cloth.  
h) Make a mark on the terminal section 1” from the cut end of the outer pipe as shown in Figure 1.13b.  
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 1.13c).  
7) Chimney Chase Installation - A vertical 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 1.14):  
a) The chimney chase elbow kit (80/125 PN230530, 100/150 PN 230568) 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 at roof to cover the top of the old chimney. Install the vertical terminal through this  
roof using the at roof ashing.  
FIGURE 1.13a: DIMENSION “H”  
16  
FIGURE 1.13b: CUTTING VERTICAL TERMINAL  
FIGURE 1.13c: COMPLETING VERTICAL TERMINAL INSTALLATION  
17  
WARNING  
• Do not attempt to construct a vertical vent system inside a chimney that is used to vent a replace or other  
appliances.  
• Do not attempt to construct a vertical vent system inside a chimney ue adjacent to another ue used by a replace  
or other appliances.  
FIGURE 1.14: CHIMNEY CHASE INSTALLATION  
18  
8) Condensate Drain Line - In systems where a concentric vent is used, all condensate which forms in the boiler or  
vent system collects in both the condensate vent adapter and the sump under the heat exchanger and leaves the  
boiler through the condensate trap. This trap allows condensate to drain from the boiler and vent while retaining  
ue gases. A length of corrugated drain hose is supplied with the boiler and is connected to the trap as shown  
in Figure 1.15. This hose may be routed through the back of the boiler or to the left side through the knockout  
provided. Route this hose to a drain or other suitable point for disposal. Note the following when disposing of the  
condensate:  
a) If the condensate drain line must be extended, construct the extension from PVC or CPVC pipe. Insert the  
hose provided with the boiler into the end of the extension as shown in Figure 1.15.  
b) Condensate is slightly acidic. Do not use metallic pipe or ttings in the condensate drain line. Do not route  
the drain line through areas that could be damaged by leaking condensate.  
c) Some jurisdictions may require that the condensate be neutralized before being disposed of. Dispose of  
condensate in accordance with local codes.  
d) Do not route, or terminate, the condensate drain line in areas subjected to freezing temperatures.  
e) If the point of condensate disposal is above the trap, it will be necessary to use a condensate pump to  
move the condensate to the drain. In such cases, select a condensate pump that is approved for use  
with condensing furnaces. If overow from this pump would result in property damage, select a pump  
with an overow switch and use this switch to shut down the boiler. Alternatively, if heat is a necessity,  
use the overow switch to trigger an alarm.  
f) Do not attempt to move the trap from the location shown in Figure 1.15. Do not attempt to substitute  
another trap for the one provided with the boiler.  
g) The vent shown in Figure 1.15 must be left open for the trap to work properly.  
FIGURE 1.15: CONDENSATE DRAIN LINE ASSEMBLY  
19  
Manufacturer of Hydronic Heating Products  
P.O. Box 14818 3633 I. Street  
Philadelphia, PA 19134  
PN: 980241 Rev. 0  
BWC - 12/07  

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