Crown Boiler BWC070 Configuration guide

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.

VII Venting
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 7.4.
* 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.
A. Vent System Design
There are four basic 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.
• Horizontal (“Side Wall”) Twin Pipe Venting - Vent system exits the building through an outside wall.
Combustion air and flue gas are routed between the boiler and outdoors using separate pipes.
• 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.
• Vertical Twin Pipe Venting - Vent system exits the building through a roof. Combustion air and flue gas are
routed between the boiler and outdoors using separate pipes.
All of these systems are considered “direct vent” because in all of them air for combustion is drawn directly from
the outdoors into the boiler. A description of all of these venting options are shown in Tables 7.1 and 7.9. For clarity,
these vent options are numbered from 1 to 6. One of the vent option columns in Tables 7.1 or 7.9 must match the
planned vent and air intake system exactly. In addition, observe the following guidelines:
1) Approved vent systems - Use only one of the approved vent systems shown in Tables 7.4 or 7.5. These vent systems
fall into two basic categories:
• Concentric Vent System - The standard boiler is supplied with a concentric vent system having a maximum
usable length of 25” (Figure 1.1). For longer runs, additional straight lengths and elbows are available from
Crown. In some cases, larger diameter concentric pipe must be used. Each Crown concentric vent component
consists of an inner pipe of polypropylene and the outer pipe of steel. Integral gaskets on each concentric fitting
provide a gas tight seal. A list of all Crown concentric vent components is shown in Table 7.4.
In this manual, concentric pipe sizes are called out in terms of the inner and outer pipe nominal diameters in
millimeters. For example, “60/100mm” pipe consists of a 60mm exhaust pipe inside a 100mm diameter outer pipe.
• Twin Pipe Vent Systems - Approved vent systems are made of a special stainless steel alloy (AL29-4C) for
protection against corrosive flue gas condensate. They are designed to provide a gas tight seal at all joints and
seams so that flue gas does not enter the building. Each approved vent system has a unique method for installation
- do not attempt to mix components from different vent systems. A list of approved twin pipe vent systems is
shown in Table 7.5. Note that a special vent collar (Crown PN 230510) is required if the boiler is to be vented
with one of the approved stainless vent systems.
11
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.).

12
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.

13
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 60/100 mm
CONCENTRIC
3” 80/125 mm
CONCENTRIC
AIR INTAKE PIPE SIZE 3”
MAXIMUM LENGTH
VENT
BWC070 32ft 55ft 55ft
BWC090 32ft 55ft 55ft
BWC120 18ft 55ft 55ft
INLET
BWC070 32ft 55ft 55ft
BWC090 32ft 55ft 55ft
BWC120 18ft 55ft 55ft
MINIMUM LENGTH
VENT
BWC070 10in 2ft 2ft
BWC090 10in 2ft 2ft
BWC120 10in 2ft 2ft
INLET
BWC070 10in 2ft 2ft
BWC090 10in 2ft 2ft
BWC120 10in 2ft 2ft
VENT TERMINAL
60/100 mm
CONCENTRIC
CROWN
#230511 Crown 230531
CONCENTRIC
or 230540
SNORKEL
AIR INTAKE TERMINAL 3” 90 ELBOW
VENT MATERIAL
CROWN
60/100mm
VENT
COMPONENTS
SHOWN IN
TABLE 7.4a
(Note #1)
APPROVED
STAINLESS
STEEL VENT
SYSTEM
SHOWN IN
TABLE 7.5
CROWN
80/125mm VENT
COMPONENTS
SHOWN IN
TABLE 7.4b
AIR INTAKE MATERIAL GALVANIZED
OR PVC
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.
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.

14
FIGURE 7.2: HORIZONTAL CONCENTRIC VENTING
(VENT OPTION 1,3)
FIGURE 7.3: HORIZONTAL TWIN PIPE VENTING (VENT OPTION 2)

15
TABLE 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 STANDARD BOILER
230520 TERMINAL SECTION 60/100mm 1 INCLUDED WITH STANDARD BOILER
230522 WALL GROMMET 60/100mm 1 INCLUDED WITH STANDARD BOILER
230505 39” STRAIGHT 60/100mm 1 OPTIONAL - MAY NOT BE CUT
230504 78” STRAIGHT 60/100mm 1 OPTIONAL - MAY NOT BE CUT
230506 19 1/2” STRAIGHT 60/100mm 1 OPTIONAL - CAN BE CUT
230507 90 DEGREE ELBOW 60/100mm 1 OPTIONAL
230508 45 DEGREE ELBOW 60/100mm 1 OPTIONAL
230515 39” STRAIGHT 80/125mm 1 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)
CROWN PN DESCRIPTION SIZE
USED ON
VENT
OPTION #
COMMENTS
230527 90 DEGREE EL (STANDARD) 80/125mm 3,6
230528 90 DEGREE EL (SWEEP) 80/125mm 3,6
230526 45 DEGREE EL 80/125mm 3,6
230517 19 1/2” STRAIGHT 80/125mm 3,6 CAN BE CUT
230515 39” STRAIGHT 80/125mm 3,6 CAN BE CUT
230518 39” STRAIGHT 80/125mm 3,6 MAY NOT BE CUT
230519 78” STRAIGHT 80/125mm 3,6 MAY NOT BE CUT
230525 TELESCOPING STRAIGHT 80/125mm 3,6 ADJUSTABLE FROM 12-1/2” TO 16-1/2
230531 HORIZONTAL TERMINAL 80/125mm 3
230540 SNORKEL KIT 80/125mm 3 (NOTE #1)
230532 VERTICAL TERMINAL 80/125mm 6 (NOTE #2)
230533 FLAT ROOF FLASHING 80/125mm 6
230535 SLOPED ROOF FLASHING 80/125mm 6 (NOTE #3)
230530 SUPPORT ELBOW WITH
CHIMNEY CHASE BRACKET 80/125mm 6 (NOTE #4)
230536 SUPPORT BAND 80/125mm 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.

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)
MANUFACTURER VENT
SYSTEM SIZE COMPONENT PART NUMBER
HEAT FAB
SAF-T
VENT
EZ SEAL
3 BOILER COLLAR CROWN 230510
3 WALL THIMBLE HEAT FAB 7393, 7393GCS, 5391CI
3 HORIZONTAL TERMINAL CROWN 230511
3 VERTICAL TERMINAL HEAT FAB 9392
PROTECH
SYSTEMS
INC.
FASNSEAL
3 BOILER COLLAR CROWN 230510
3 WALL THIMBLE FSWT3
3 HORIZONTAL TERMINAL CROWN 230511
3 VERTICAL TERMINAL FSBS3
Z-FLEX
SVE
SERIES III
(“Z-VENT
III”)
3 BOILER COLLAR CROWN 230510
3 WALL THIMBLE 2SVSWTEF03
3 HORIZONTAL TERMINAL CROWN 230511
3 VERTICAL TERMINAL 24SVSTPF03
METAL-FAB CORR/
GUARD
3 BOILER COLLAR CROWN 230510
3 WALL THIMBLE CGSWWPK(3”)
3 HORIZONTAL TERMINAL CROWN 230511
3 VERTICAL TERMINAL CGSWHTM(3”)
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

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 - 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

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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 3”
80/125 mm CONCENTRIC
AIR INTAKE PIPE SIZE 3”
MAXIMUM LENGTH
VENT
BWC070 49.5ft 49.5ft
BWC090 49.5ft 49.5ft
BWC120 49.5ft 49.5ft
INLET
BWC070 49.5ft 49.5ft
BWC090 49.5ft 49.5ft
BWC120 49.5ft 49.5ft
MINIMUM LENGTH
VENT
BWC070 2ft 2ft
BWC090 2ft 2ft
BWC120 2ft 2ft
INLET
BWC070 2ft 2ft
BWC090 2ft 2ft
BWC120 2ft 2ft
VENT TERMINAL
STRAIGHT TERMINAL
BY VENT SYSTEM MFR.
(TABLE 7.5) CROWN #230532
CONCENTRIC TERMINAL
(TABLE 7.4b)
AIR INTAKE TERMINAL 3” 180° ELBOW
(FIGURE 7.10)
VENT MATERIAL APPROVED STAINLESS
STEEL VENT SYSTEM
CROWN 80/125 mm VENT
COMPONENTS SHOWN IN
TABLE 7.4b
AIR INTAKE MATERIAL GALVANIZED OR PVC
TABLE 7.8: VENT/ AIR INTAKE FITTING EQUIVALENT LENGTH
VENT FITTING EQUIVALENT LENGTH (ft)
60/100mm 90° CONCENTRIC ELBOW 4.5
60/100mm 45° CONCENTRIC ELBOW 4.0
80/125mm 90° CONCENTRIC ELBOW 8.5
80/125mm 90° SWEEP CONCENTRIC ELBOW 5.5
80/125mm 45° CONCENTRIC ELBOW 3.0
80/125mm 90° CONCENTRIC SUPPORT ELBOW 8.5
3” SINGLE WALL 90° ELBOW 5.5
3” SINGLE WALL 45° ELBOW 4.0

20
FIGURE 7.10: VERTICAL TWIN PIPE VENT SYSTEM (VENT OPTION 5)
FIGURE 7.11: VERTICAL CONCENTRIC VENT SYSTEM (VENT OPTION 6)

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

22
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.

FIGURE 7.21: DIMENSION “L”
23
FIGURE 7.20: INSTALLATION OF REDUCING ELBOW ON CONCENTRIC BOILER COLLAR

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 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

FIGURE 7.25: ATTACHING 60/100mm TERMINAL SECTION
25
FIGURE 7.24: PREPARING 60/100mm TERMINAL SECTION FOR INSTALLATION IN THE WALL

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 19 1/2” Straight
230515 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
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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
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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
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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
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