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D E S I G N E D T O L E A D
BWC Series
High Effi ciency Gas-Fired Hot Water
Direct Vent Condensing Boilers
INSTALLATION INSTRUCTIONS
These instructions must be affi xed on or adjacent to the boiler.
Models:
WARNING: Improper installation, adjustment, alteration,
service or maintenance can cause property damage, injury,
• BWC150
or loss of life. For assistance or additional information, con-
• BWC225
sult a qualifi ed installer, service agency or the gas
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Table of Contents I. Product Description 2 II. Specifications 2 III. Before Installing 3 IV. Locating The Boiler 3 V. Air For Ventilation 5 VI. Venting 7 Vent System Design 7 Removing An Existing Boiler From Common Chimney 14 Vent/Intake System Assembly 14 VII. Gas Piping 20 VIII. System Piping 21 General System Piping Precautions 21 System Design 21 Standard Piping Installation Requirements 31 Piping
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I Product Description The BWC is an aluminum gas fired condensing boiler designed for use in forced hot water heating systems requir- ing supply water temperatures of 180°F or less. This boiler may be vented vertically or horizontally with combus- tion air supplied from outdoors. This boiler is not designed for use in gravity hot water systems or systems contain- ing significant amounts of dissolved oxygen. II Specifications Figure 2.1: General Configuration Table 2.2: Specifications D.O.E. VENT CO
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III Before Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the National Fuel Gas Code, ANSI Z223.1. • Where required by the authority having jurisdiction, this installation must conform to the Standard for Controls and Safety Devices
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Figure 4.1: Clearances To Combustible Or Non-combustible Material Table 4.2: Clearances From Vent Piping To Combustible Construction MINIMUM CLEARANCE TO COMBUSTIBLE TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE MATERIAL HEAT FAB SAF-T VENT AT LEAST ONE SIDE OPEN, PROTECH FASNSEAL VERTICAL OR 1” COMBUSTIBLE MATERIAL ON A Z-FLEX Z-VENT III HORIZONTAL MAXIMUM OF THREE SIDES FLEX-L STAR-34 HEAT FAB SAF-T VENT PROTECH FASNSEAL HORIZONTAL OR VERTICAL 2-1/2” ENCLOSED ON ALL FOUR SIDES Z-FLEX Z-VENT
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WARNING OUTDOOR COMBUSTION AIR MUST BE PIPED TO THE AIR INTAKE. NEVER PIPE COMBUSTION AIR FROM AREAS CONTAINING CONTAMINATES SUCH AS SWIMMING POOLS AND LAUNDRY ROOM EXHAUST VENTS. CONTAMINATED COMBUSTION AIR WILL DAMAGE THE BOILER AND MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. V Air for Ventilation Air for combustion must always be obtained directly from outdoors, however sufficient air for ventilation must still be provided in the boiler room. Air for ventilation is r
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Figure 5.1: Boiler Installed In A Confined Space, Ventilation Air From Inside • If the total volume of both the boiler room and the room to which the openings connect is less than 50 cubic feet per 1000 BTU/hr of total appliance input, install a pair of identical openings into a third room. Connect addi- tional rooms with openings until the total volume of all rooms is at least 50 cubic feet per 1000 BTU/hr of input. • The “free area” of an opening takes into account the blocking effect of mesh
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VI Venting WARNING Failure to vent this boiler in accordance with these instructions could result in unreliable boiler operation, severe damage to the boiler or property, or unsafe operation: * Do not attempt to vent this boiler with galvanized, PVC, or any other vent system not listed in Table 4. * 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. *
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The Vent Option #1 column in Table 6.2a describes a horizontal direct vent system using 3” vent pipe. From this column, we see that a BWC150 may have a vent length of up to 55ft. The first 90 elbow and the termination elbow are not considered. From Table 6.6, the equivalent length of the 3” 45 elbow is 4ft and the equivalent length of the 3” 90 degree elbow is 5.5ft. The maximum allowable run of straight pipe on this system is therefore: 55ft – 4 ft – 5.5ft = 40ft Since the
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• 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 the vent and air intake 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 publi
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FIGURE 6.3a: LOCATION OF VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE FIGURE 6.3b: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS FIGURE 6.3c: POSITIONING VENT TERMINAL UNDER OVERHANGS 10
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• 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 the terminal is 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. 6) Permitted Terminals for Vertical Venting (Vent Options 6, 7) - A rodent screen is instal
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TABLE 6.2b: SUMMARY OF VERTICAL VENTING OPTIONS VENT OPTION # 6 7 CLASSIFICATION USED IN THIS VERTICAL VERTICAL MANUAL DIRECT VENT DIRECT VENT ILLUSTRATED IN FIGURE 6.4 6.4 VENT PIPE STRUCTURE ROOF ROOF PENETRATION AIR INTAKE PIPE STRUCTURE ROOF ROOF PENETRATION VENT PIPE SIZE 3” 4” AIR INTAKE PIPE SIZE 4” 4” BWC150 49.5 FT N.R. BWC225 N.R. 47 FT BWC150 52 FT N.R. BWC225 N.R. 52 FT RODENT SCREEN BY VENT SYSTEM EXHAUST TERMINAL MANUFACTURER. SAME DIAMETER AS VENT SYSTEM. SEE TABLE 6.5. AIR
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TABLE 6.5: PERMISSIBLE VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS WALL HORIZONTAL VERTICAL MANUFACTURER VENT SYSTEM SIZE THIMBLES TERMINATION TERMINATION 7393GC ELBOW: 7314TERM 3 7393GCS TEE: 7390TEE 9392 SAF-T VENT 5391CI HEAT FAB EZ SEAL 7493GC ELBOW: 7414TERM 4 7493GCS 9492 TEE: 7490TEE 5491CI ELBOW: FSELB9003 + FSBS3 3 FSWT3 FSBS3 PROTECH TEE: FSTT3 SYSTEMS FASNSEAL ELBOW: FSELB9004 + FSBS4 INC. 4 FSWT4 FSBS4 TEE: FSTT4 ELBOW: 2SVSTEX0390 3 2SVSWTEF03 24SVSTPF03 TEE: 2SVSTTF03 SVE Z-FLEX
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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 rem
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2) Assembly of Flex-L-Intl. Star-34 Vent System: a) Star-34 General Notes: • Do not cut Star-34 vent components. • Support horizontal piping sections at intervals of 48” or less. • Vertical venting systems must be supported by at least one Star-34 Fire stop. An additional vertical support is required after any offset. • Orient Star-34 components so that the arrows on the piping labels are in the direction of flue gas flow. b) Start assembly of the vent system at the
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3) Assembly of Z-Flex Z-Vent III: a) General Notes: • Non-expanded ends of SVE Series III piping sections may be cut using aviation snips or a 24 thread per inch hacksaw. File or sand the cut end smooth before assembling. Expanded ends may be cut to adapt the SVE series III to the vent collar or Crown coaxial terminal. See the following instructions. • Support horizontal piping sections at intervals of 48” or less. • Vertical venting systems must be supported by at le
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4) Assembly of Heat Fab Saf-T Vent EZ Seal: a) Saf-T Vent General Notes: These instructions cover the installation of Saf-T Vent EZ Seal. Saf-T Vent EZ Seal piping has integral gaskets installed in the female ends of the pipe which seal the joints. • In general, Saf-T Vent pipe sections may not be cut. Exceptions to this are the Saf-T Vent slip connector and connections to the boiler vent collar. In these cases, use a sharp pair of aviation snips, an abrasiv
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5) Assembly of Protech FasNSeal a) FasNSeal General Notes: • Do not cut 4” FasNSeal pipe. Consult FasNSeal instructions for method of cutting other 3” pipe. • Orient FasNSeal vent components so that the arrows on the piping labels are in the direction of flue gas flow. • Support horizontal piping sections at intervals of 6 feet or less. • Vertical venting systems must be supported by at least one FasNSeal support. An additional vertical support is required after any offs
