Crown Boiler CWD060 User manual

WARNING: Improper installation,
adjustment, alteration, service or
maintenance can cause property
damage, injury, or loss of life. For
assistance or additional information,
consult a qualied installer, service
agency or the gas supplier. Read
these instructions carefully before
installing.
Models:
• CWD060
• CWD083
• CWD110
• CWD138
• CWD165
• CWD193
• CWD220
• CWD245
CWD Series
Gas-Fired Direct Vent Hot Water Boilers
INSTALLATION INSTRUCTIONS
These instructions must be afxed on or adjacent to the boiler
DESIGNED TO LEAD
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com
Equipped with Honeywell
S9361A Control System
9902339

2
2

1
1
FOLLOW ALL INSTRUCTIONS and warnings
printed in this manual and posted on the boiler.
INSPECT THE BOILER ANNUALLY. To keep your
boiler safe and efficient, have a service technician
follow the Service checklist near the end of this
manual.
IF YOU ARE NOT QUALIFIED to install or service
boilers, do not install or service this one.
THE BOILER MAY LEAK WATER at the end of
its useful life. Be sure to protect walls, carpets,
and valuables from water that could leak from the
boiler.
PROTECT YOUR HOME IN FREEZING
WEATHER. A power outage, safety lockout, or
component failure will prevent your boiler from
lighting. In winter, your pipes may freeze and
cause extensive property damage. Do not leave
the heating system unattended during cold weather
unless alarms or other safeguards are in place to
prevent such damage
DO NOT BLOCK AIR FLOW into or around the
boiler. Insufficient air may cause the boiler to
produce carbon monoxide or start a fire.
KEEP FLAMMABLE LIQUIDS AWAY from the
boiler, including paint, solvents, and gasoline.
The boiler may ignite the vapors from the liquids
causing explosion or fire.
KEEP CHILDREN AND PETS away from hot
surfaces of the boiler, boiler piping, and vent pipe.
CARBON MONOXIDE (CO) is an odorless, deadly
gas that may be introduced into your home by
any malfunctioning fuel-burning product or vent
system failure. Consider installing CO alarms near
bedrooms in all levels of the building to warn you
and your family of potential CO exposure.
READ THIS ENTIRE MANUAL before attempting
installation, start-up, or service. Improper
installation, adjustment, alteration, service, or
maintenance may cause serious property damage,
personal injury, or death.
DO NOT DISCONNECT PIPE FITTINGS on the
boiler or in the heating system without first verifying
that the system is cool and free of pressure and
that your clothing will protect you from a release
of hot water or steam. Do not rely solely on the
boiler’s temperature and pressure gage when
making this judgment.
USE PROPER PERSONAL PROTECTION
EQUIPMENT when servicing or working near the
boiler. Materials of construction, flue products, and
fuel contain alumina, silica, heavy metals, carbon
monoxide, nitrogen oxides, and/or other toxic or
harmful substances that can are hazardous to
health and life and that are known to the State of
California to cause cancer, birth defects, and other
reproductive harm.
INSTALL ALL GUARDS, cover plates, and
enclosures before operating the boiler.
SIZE THE BOILER PROPERLY relative to the
design heat load or, if using domestic hot water
priority, the peak hot water load, whichever
is larger. A grossly oversized boiler will cycle
excessively and this will lead to premature failure
of the boiler and its components. Our warranty
does not apply to damage from excessive cycling.
ADHERE TO ALL LOCAL CODE
REQUIREMENTS. Contact your local code
inspector prior to installation. In the absence of
a local code, adhere to the National Fuel Gas
Code ANSI Z223.1/NFPA 54 or CAN/CSA B149.1,
Natural Gas and Propane Installation Code.
ALL WIRING must comply with the National
ElectrIcal Code ANSI/NFPA 70 (in the USA) or the
Canadian Electrical Code CSA C22.1 (in Canada)
and any local regulations.
WARNINGS FOR THE HOMEOWNER
WARNINGS FOR THE INSTALLER

2
TABLE OF CONTENTS
I Product Description 3
II Specications 3
III Before Installing 4
IV Locating the Boiler 4
V Air for Combustion and Ventilation 6
VI Venting 12
Vent System Design 12
Vent System Assembly 25
VII Gas Piping 36
VIII System Piping 37
IX Wiring 42
X Start-up and Checkout 46
XI Operation 50
XII Service and Maintenance 58
XIII Troubleshooting 63
XIV Parts 67
Appendix A:Special Requirements for
Side-Wall Vented Appliances in the
Commonwealth of Massachusetts
76

3
3
I Product Description
The CWD series boiler is a cast iron gas red boiler designed for use in forced hot water heating systems. It is is a low
pressure boiler intended for use in closed heating systems with water temperatures under 240F. This boiler may be vented either
vertically or horizontally with combustion air supplied from either outdoors or (under certain conditions) indoors. It is ideal for
use in installations where a reliable source of clean indoor combustion air cannot be guaranteed.
II Specications
TABLE 2.2: SPECIFICATIONS
MODEL SECTIONS
INPUT
(MBH)
HEATING
CAPACITY
(MBH)
NET AHRI
RATING,
WATER (MBH)
AFUE
(%)
FIG 2.1
DIM. “A” (in.)
VENT
DIA. (in.)
WATER
CONTENT
(Gal.)
CWD060 3 60 51 44 85.1 16-1/8 3 2.0
CWD083 4 82.5 71 62 85.1 19-3/4 3 2.6
CWD110 5 110 94 82 85.2 23-3/8 3 3.1
CWD138 6 137.5 118 103 85.2 27 3 3.6
CWD165 7 165 142 123 85.2 30-5/8 3 OR 4 4.2
CWD193 8 192.5 165 143 85.2 34-1/8 3 OR 4 4.7
CWD220 9 220 189 164 85.2 37-3/4 3 OR 4 5.2
CWD245 10 245 211 183 85.3 41-3/8 3 OR 4 5.8
Notes:
The Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1.15.
The manufacturer should be consulted before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system opera-
tion, extensive piping systems, etc.
FIGURE 2.1: GENERAL CONFIGURATION

4
4
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 for Automatically Fired Boilers (ANSI/ASME CSD-1).
2) Read Section VI to verify that the maximum combustion air and exhaust pipe lengths will not be exceeded in the planned
installation. Also verify that the vent terminal can be located in accordance with Section VI.
3) Make sure that the boiler is correctly sized:
• For heating systems employing convection radiation (baseboard or radiators), use an industry accepted sizing method
such as the I=B=R Guide RHH published by the Air-Conditioning, Heating and Refrigeration Institute (AHRI).
• For new radiant heating systems, refer to the radiant tubing manufacturer’s boiler sizing guidelines.
• For systems including a Crown Mega-Stor indirect water heater, size the boiler to have either the Heating Capacity
required for the Mega-Stor or the I=B=R Net Rating required for the heating system, whichever results in the larger
boiler.
• For systems that incorporate other indirect water heaters, refer to the indirect water heater manufacturer’s instructions for
boiler output requirements.
4) Make sure that the boiler received is congured for the correct gas (natural or LP).
5) This boiler is not designed for use with return temperatures under 120F for a sustained period of time. Some systems, such
as those having large water contents, may require a return water bypass or other special provisions to protect the boiler
against low return temperatures. Failure to provide such provisions if needed could result in severe corrosion damage to the
boiler. For more information on when low water temperatures protection is required, and appropriate protection, see Part
VIII.
6) For installations at altitudes above 2000ft, special orice and pressure switches are required. Make sure that the boiler is
congured for use at the correct altitude.
IV Locating the Boiler
1) Boiler clearances are shown in Figure 4.1. Figure 4.1a shows clearances from the boiler when outdoor combustion air is
used. Figure 4.1b shows clearances from the boiler when combustion air is obtained from the boiler room. These minimum
clearances apply to all types of combustible construction as well as noncombustible walls, ceilings and doors. At least 24”
must be provided for servicing at the front of the boiler. This front clearance may be provided through a door, such as a
closet door. Boiler will be much easier to service if at least 12” is provided from the sides and rear of the boiler to walls.
2) Clearances from venting to combustible material depends upon the type of venting, whether the vent pipe is enclosed, and
whether the venting is vertical or horizontal. See Table 4.2 for vent clearance information.
3) Boiler may be installed on a non-carpeted combustible surface.
4) The relief valve must not be moved from the location shown in Figure 2.1.
5) When combustion air is obtained from the boiler room, a 10” clearance is required from the side of the boiler having the air
inlet collar to combustible or non-combustible obstruction (Figure 4.1b).
NOTICE
This product must be installed by a licensed plumber or gas tter when installed within the Commonwealth of Massachusetts.
See Appendix A for additional important information about installing this product within the Commonwealth of Massachusetts.
WARNING
FAILURE TO OBSERVE THE FOLLOWING LOCATION REQUIREMENTS COULD RESULT
IN A FIRE, EXPLOSION OR CARBON MONOXIDE (CO) HAZARD.

5
5
FIGURE 4.1a: CLEARANCES WHEN BOILER IS DIRECT VENTED (OUTDOOR COMBUSTION AIR IS USED)
FIGURE 4.1b: CLEARANCES WHEN COMBUSTION AIR IS OBTAINED FROM BOILER ROOM

6
6
6) The boiler should be located so as to minimize the length of the vent system.
7) Do not install this boiler in a location where gasoline or other ammable vapors or liquids will be stored or used. Do
not install this boiler in an area where large amounts of airborne dust will be present, such as a workshop. When indoor
combustion air is used, do not install in a location where sources of hydrocarbons will be stored or used. Some common
sources of hydrocarbons include bleaches, fabric softeners, paints, cleaners, refrigerants, and cat boxes. Traces of these
substances can be drawn into the boiler causing severe corrosion damage to the boiler and /or objectionable odors.
TABLE 4.2: CLEARANCES FROM VENT PIPING TO COMBUSTIBLE CONSTRUCTION
TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE
MINIMUM CLEARANCE
TO COMBUSTIBLE
MATERIAL
HEAT FAB SAF-T VENT
PROTECH FASNSEAL
PROTECH FASNSEAL W2
METAL-FAB CORR/GUARD
VERTICAL OR
HORIZONTAL
AT LEAST ONE SIDE OPEN,
COMBUSTIBLE MATERIAL ON A
MAXIMUM OF THREE SIDES
1”
HEAT FAB SAF-T VENT
PROTECH FASNSEAL
Z-FLEX Z-VENT III
METAL-FAB CORR/GUARD
HORIZONTAL OR VERTICAL
WITH OFFSETS ENCLOSED ON ALL FOUR SIDES 8”
HEAT FAB SAF-T VENT
PROTECH FASNSEAL
Z-FLEX Z-VENT III
METAL-FAB CORR/GUARD
VERTICAL WITH NO OFFSETS ENCLOSED ON ALL FOUR SIDES 6”
PROTECH FASNSEAL W2 VERTICAL OR HORIZONTAL ENCLOSED ON ALL FOUR SIDES 3”
HEAT FAB SAF-T VENT SC VERTICAL OR HORIZONTAL UNENCLOSED OR ENCLOSED ON
ALL SIDES 0”
“B” VENT CHASE USED AS PART OF
CROWN COAXIAL VENT SYSTEM* VERTICAL PER “B” VENT MANFACTUER’S INSTRUCTIONS
REFER TO “B” VENT
MANUFACTURER’S
INSTRUCTIONS
* “B” Vent is used as a chase to carry combustion air in this system - never attempt to vent a CWD boiler using “B” vent
V Air for Combustion and Ventilation
Sufcient fresh air must be supplied for both combustion and ventilation. In general, combustion air is obtained in one
of two ways:
• Direct Vent Installations – Combustion air is piped directly to the boiler inlet collar from the outdoors. This is also
sometimes called a “sealed combustion” installation.
• Direct Exhaust Installations – Combustion air is obtained from the boiler room. In some cases, openings or duct work
may be run from the outdoors to the boiler room, however the ducting is not connected directly to the boiler.
Air for ventilation is required to keep various boiler components from overheating and is always obtained from indoors.
To ensure an adequate combustion and ventilation air supply, perform the following steps:
WARNING
• INSUFFICIENT COMBUSTION AIR SUPPLY MAY RESULT IN THE PRODUCTION AND
RELEASE OF DEADLY CARBON MONOXIDE (CO) INTO THE HOME WHCH CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH.

7
7
Step 1: Determine whether the boiler is to be installed in a building of unusually tight construction
A good denition of “unusually tight construction” is construction having all of the following features:
• Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less
with openings gasketed and sealed.
• Weather stripping has been added on openable windows and doors.
• Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates and oors,
between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and at other
openings.
Step 2: Determine whether the boiler is to be installed in a conned space
A conned space is dened by the National Fuel Gas Code as having a volume less than 50 cubic feet per 1000 BTU/hr
input of all appliances installed in that space. To determine whether the boiler room is a conned space:
1) Total the input of all appliances in the boiler room in thousands of BTU/hr. Round the result to the next highest 1000 BTU/
hr.
2) Find the volume of the room in cubic feet. The volume of the room in cubic feet is:
Length (ft) x width (ft) x ceiling height (ft)
In calculating the volume of the boiler room, consider the volume of adjoining spaces only if no doors are installed between
them. If doors are installed between the boiler room and an adjoining space, do not consider the volume of the adjoining
space, even if the door is normally left open.
3) Divide the volume of the boiler room by the input in thousands of BTU/hr. If the result is less than 50, the boiler room is a
conned space.
Example:
A CWD245 and a water heater are to be installed in a room measuring 6ft – 3 in x 7ft with an 8 ft ceiling. The water heater
has an input of 30000 BTU/hr:
Total input in thousands of BTU/hr = (245000 BTU/hr + 30000 BTU/hr) / 1000 = 275
Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft3
350/275 = 1.27. Since 1.27 is less than 50, the boiler room is a conned space.
Step 3: Decide whether the boiler will be direct vented or direct exhausted
The boiler must be direct vented (combustion air piped directly to the boiler) if:
• The boiler is to be installed in a laundry room
• The building in which the boiler is installed has an indoor pool.
• The boiler is located in an area having any of the contaminants described in Section IV.
It is also strongly recommended that combustion air be piped from outside when the boiler is installed in a building of
unusually tight construction.
Step 4: If the boiler is Direct Vented, Provide Air as Follows (If Indoor Combustion Air is used,
Skip to Step 5):
1) Combustion air piping must not exceed the maximum lengths called for in Section VI.
2) Although combustion air is obtained directly from outdoors, openings may be required into the boiler room to allow for
adequate equipment ventilation. The following guidelines apply regardless of whether or not the building is of unusually
tight construction:
Unconned Space– Natural inltration into the boiler room will provide adequate air for ventilation without additional
openings into boiler room.
Conned Space – Provide two openings into the boiler room, one near the oor and one near the ceiling. The top edge of
the upper opening must be within 12” of the ceiling and the bottom edge of the lower opening must be within 12” of the

8
8
oor (Fig 3). The minimum opening dimension is 3 inches.
• If the CWD boiler is the only gas-burning appliance in the boiler room, these openings must each have a free area of 100
square inches.
• If other gas-burning appliances are in the boiler room, size the openings in accordance with the appliance manufacturer’s
instructions or the National Fuel Gas Code. Minimum opening free area is 100 square inches regardless of opening
requirements for other appliances.
• 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 additional 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, grills, and louvers. Where screens are used,
they must be no ner than ¼” (4 x 4) mesh.
Step 5: If Indoor Combustion Air is Used, Provide Air as Follows:
1) Buildings of other than unusually tight construction:
Unconned Space– Natural inltration into the boiler room will normally provide adequate air for combustion and
ventilation without additional louvers or openings into boiler room.
Conned Space – Provide two openings into the boiler room, one near the oor and one near the ceiling. The top edge of
the upper opening must be within 12” of the ceiling and the bottom edge of the lower opening must be within 12” of the
oor (Fig 5.1).
• Each opening must have a free area of 1 square inch per 1000 BTU/hr input of all gas burning appliances in the boiler
room. The minimum opening dimension is 3 inches. Minimum opening free area is 100 square inches per opening.
• 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 additional 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, grills, and louvers. Where screens are used,
they must be no ner than ¼” (4 x 4) mesh.
2) Buildings of unusually tight construction:
If at all possible, direct vent the boiler. Where the boiler must be installed in unusually tight construction and cannot be
direct vented, openings must be installed between the boiler room and the outdoors or a ventilated space, such as an attic
or crawl space, which communicates directly with the outdoors. Two openings are required. The top edge of the upper
opening must be within 12 inches of the ceiling. The bottom edge of the lower opening must be within 12 inches of the
oor. Size openings and ducts as follows:
• Vertical ducts or openings directly outdoors (Fig 5.2, Fig 5.3, Fig 5.4) – Each opening must have a free cross sectional
area of 1 square inch per 4000 BTU/hr of the total input of all gas-red appliances in the boiler room but not less than 100
square inches. Minimum opening size is 3 inches.
• Openings to outdoors via horizontal ducts (Fig 5.5) - Each opening must have a free cross sectional area of 1 square
inch per 2000 BTU/hr of the total input of all gas red appliances in the boiler room but not less than 100 square inches.
Minimum opening size is 3 inches.
• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are used,
they must be no ner than ¼” (4 x 4) mesh.

9
9
FIGURE 5.1: BOILER INSTALLED IN A CONFINED SPACE - VENTILATION OR
COMBUSTION / VENTILATION AIR FROM INSIDE
FIGURE 5.2: ALL AIR FROM OUTSIDE USING VENTILATED CRAWL SPACE AND ATTIC

10
10
FIGURE 5.3: ALL AIR FROM OUTSIDE USING VENTILATED ATTIC
FIGURE 5.4: ALL AIR FROM OUTSIDE USING OPENINGS INTO BOILER ROOM

11
11
FIGURE 5.5: ALL AIR FROM OUTSIDE USING HORIZONTAL DUCTS INTO BOILER ROOM

12
12
VI Venting
A. Vent System Design
There are three basic ways to vent the CWD boiler:
• Horizontal (“side wall”) Venting - Vent system exits the building through an outside wall. Combustion air is either
obtained through a separate pipe from outside (a “direct vent” installation) or obtained from the boiler room (a “direct
exhaust” installation).
• Vertical Non-Coaxial Venting - Vent system exits the building through a roof. Combustion air is either obtained
through a separate pipe from outside (a “direct vent” installation) or obtained from the boiler room (a “direct exhaust”
installation).
• Vertical Coaxial Venting - Vent system exits the building through a roof. A portion of the vent system is coaxial, meaning
that it consists of a “pipe within a pipe”. Flue gasses exit the building through the inner pipe and combustion air is drawn
through the space between the two pipes.
For each of the above three basic methods, there are several variations, resulting in a total of 13 options for venting
the CWD boiler. A description of each of these venting options is listed in Tables 6.1a-6.1c. For clarity, these vent options
are numbered from 1 to 13 in Table 6.1. One of the vent option columns in Table 6.1 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 Table 6.8. These systems are made of a
special stainless steel alloy (AL29-4C) for protection against corrosive ue gas condensate. They are also designed to
provide a gas tight seal at all joints and seams so that ue gas does not enter the building. Each approved vent system has
unique method for installation - do not attempt to mix components from different vent systems. The only exceptions are:
• Heat Fab Saf-T Vent SC may be combined with Saf-T Vent EZ Seal.
• Protech FasNSeal W2 may be combined with Protech FasNSeal.
See the vent installation section of this manual for information on how this can be done.
Heat Fab Saf-T Vent SC is a double wall vent system which can be used in two ways on CWD installations. In vertical
coaxial vent systems (Vent Options 12 and 13), the space between the inner and outer pipes is used as a conduit to bring
combustion air to the boiler. In Horizontal (Vent Options 1 to 5) and Vertical (Option 6 to 10) vent systems, Saf-T Vent SC
can be used to obtain a 0” clearance to combustible construction. When this is done, the space between the inner and outer
pipes is used for ventilation, but boiler combustion air comes from elsewhere.
Protech FasNSeal W2 is also a double wall vent system. In some cases, it can used to obtain closer clearances to
combustible construction than are possible using Protech FasNSeal (see Table 4.2). The space between the inner and outer
pipes on FasNSeal W2 cannot be used as a combustion air conduit.
The Crown Vertical coaxial vent system (Vent Option 11) is similar to that constructed using Heat Fab Saf-T Vent SC
except it is constructed by running one of the 3” single wall vent systems shown in Table 6.8 inside 5” type “B” vent. The
space between the 3” vent and the “B” vent forms a conduit to bring combustion air to the boiler. The advantage of this
system is that it can be constructed using any of the vent systems shown in Table 6.8 except for Heat Fab Saf-T Vent SC
and Protech FasNSeal W2. No turns are permitted in the coaxial section of this system.
WARNING
• FAILURE TO VENT THIS BOILER IN ACCORDANCE WITH THESE INSTRUCTIONS MAY
RESULT IN UNRELIABLE BOILER OPERATION, PROPERTY DAMAGE AND/OR THE RELEASE
OF FLUE GASES, WHICH CONTAIN DEADLY CARBON MONOXIDE (CO), INTO THE HOME,
WHICH CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.
• DO NOT ATTEMPT TO VENT THIS BOILER WITH GALVANIZED, PVC, CPVC, RADEL® OR
ANY OTHER VENT SYSTEM NOT LISTED IN TABLE 6.8.
• DO NOT ATTEMPT TO MIX COMPONENTS FROM DIFFERENT APPROVED VENT SYSTEMS.
• DO NOT INSTALL A BAROMETRIC DAMPER OR DRAFTHOOD ON THIS BOILER.
• DO NOT ATTEMPT TO USE THE VENT SYSTEM FOR THIS BOILER WITH ANY OTHER
APPLIANCE.
• MOISTURE AND ICE MAY FORM ON THE SURFACES AROUND THE VENT TERMINATION.
TO PREVENT DETERIORATION, SURFACES SHOULD BE IN GOOD REPAIR (SEALED,
PAINTED, ETC.)

13
13
TABLE 6.1a: SUMMARY OF HORIZONTAL VENTING OPTIONS
VENT OPTION # 1 2 3 4 5
CLASSIFICATION USED IN THIS
MANUAL
HORIZONTAL
DIRECT VENT
HORIZONTAL
DIRECT VENT
(RESERVED
FOR FUTURE
USE)
HORIZONTAL
DIRECT
EXHAUST
HORIZONTAL
DIRECT
EXHAUST
ILLUSTRATED IN FIGURE 6.2a OR 6.2b 6.2a OR 6.2b 6.3 6.3
VENT PIPE STRUCTURE
PENETRATION WALL WALL WALL WALL
AIR INTAKE PIPE STRUCTURE
PENETRATION WALL WALL N.A. N.A.
VENT PIPE SIZE 3” 4” 3” 4”
AIR INTAKE PIPE SIZE 4” 4” N.A. N.A.
MAXIMUM VENT
PIPE LENGTH
CWD060 - CWD138 55 FT 55 FT 55 FT 55 FT
CWD165 35 FT 55 FT 35 FT 55 FT
CWD193 25 FT 55 FT 25 FT 55 FT
CWD220 15 FT 55 FT 15 FT 55 FT
CWD245 N.R. 55FT 10 FT 55 FT
MAXIMUM
INTAKE PIPE
LENGTH
CWD060 - CWD138 60 FT 60 FT N.A. N.A.
CWD165 40 FT 60 FT N.A. N.A.
CWD193 30 FT 60 FT N.A. N.A.
CWD220 20 FT 60 FT N.A. N.A.
CWD245 N.R. 60 FT N.A. N.A.
EXHAUST TERMINAL
3” 90 ELBOW,
TEE, OR
CROWN
COAXIAL
TERMINAL
#50-003
4” 90 ELBOW,
TEE, OR
CROWN
COAXIAL
TERMINAL
#50-004
3” 90 ELBOW
OR TEE
4” 90 ELBOW
OR TEE
AIR INTAKE TERMINAL
4” 90 ELBOW
OR CROWN
COAXIAL
TERMINAL
#50-003
4” 90 ELBOW
OR CROWN
COAXIAL
TERMINAL
#50-004
N.A. N.A.
VENT MATERIAL APPROVED VENT SYSTEM SHOWN IN TABLE 6.8
AIR INTAKE MATERIAL GALVANIZED OR PVC N.A. N.A.
“N.R” - Not recommended “N.A.” - Not applicable

14
14
FIGURE 6.2a: HORIZONTAL DIRECT VENTING USING SEPARATE TERMINALS (VENT OPTIONS 1-2)
FIGURE 6.2b: HORIZONTAL DIRECT VENTING USING COAXIAL TERMINAL (VENT OPTIONS 1-2)

15
15
FIGURE 6.3: HORIZONTAL DIRECT EXHAUST VENT SYSTEM (VENT OPTIONS 4,5)
2) Maximum Vent and Air Intake Lengths - The maximum length of the vent air intake piping depends upon the vent option
selected, the vent pipe size, and the boiler size. See Table 6.1 for the maximum vent length. In addition to the maximum
length of piping shown in Table 6.1, the following ttings may also be used:
• Horizontal Vent Systems: One 90 deg. elbow
• Vertical Vent Systems: Two 90 deg. elbows
• Vertical Coaxial Vent Systems: Two 90 deg. elbows
• Air Intake Systems: Two 90 deg. elbows
If additional elbows are desired, the maximum allowable vent length must be reduced by the amount shown in Table 6.9 for
each additional elbow used. Note: Termination ttings do not need to be counted when counting additional elbows.
Example:
A 3” vent system is planned for a horizontal direct vented CWD165 which has the following components:
2 ft vertical pipe
1 90 elbow
5 ft horizontal pipe
1 90 elbow
3 ft horizontal pipe
1 45 elbow
4 ft horizontal pipe
1 termination elbow
The Vent Option #1 column in Table 6.1a describes a horizontal direct vent system using 3” vent pipe. From this column, we
see that a CWD165 may vent length of up to 35ft. The rst 90 elbow and the termination elbow are not considered. From
Table 6.9, 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:
35ft – 4 ft – 5.5ft = 25.5ft
Since the planned installation has only 14 ft of straight pipe, the planned vent length is acceptable.
3) Minimum Vent / Exhaust Pipe Length - Minimum vent length is 2ft. Minimum air inlet length is 0ft.

16
16
3) Permitted Terminals for Horizontal Venting (Vent Options 1 - 5) - Table 6.1a shows permitted types of terminals for both
the vent and air inlet systems. On horizontal direct vent systems using 4” air inlet pipe (Vent Options 1 and 2), the following
Crown co-axial terminals may be used. These terminals have the advantage of requiring only one wall penetration. Part
numbers for the Crown coaxial terminals are as follows:
• 3” Vent - 50-003
• 4” Vent - 50-004
When separate vent and air intake terminals are used, or when the boiler uses indoor combustion air, the vent terminal
is either a tee or an elbow supplied by the vent system manufacturer and equipped with a rodent screen. Vent system
manufacturer’s part numbers for these ttings are shown in Table 6.8. In some cases, the elbows and tees shown in Table
6.8 require separate adaptors and/or rodent screens. When this is the case, vent manufacturer part numbers for these
additional parts are shown in Table 6.8 along with the termination tting.
When Heat Fab Saf-T Vent SC is used, the Heat Fab 5300CI or 5400CI tting is used between the last piece of Saf-T
Vent CI and the terminal. These ttings physically adapt from the CI pipe to the terminal and also provide ventilation
openings which must remain open for the Saf-T Vent CI to maintain its clearance rating.
Except when the Crown 50-003 or 50-004 coaxial terminals are used, the air intake tting on a horizontal direct vent
system (Options 1 - 2) is always a 90 degree elbow with a rodent screen. 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 6.2a.
4) Horizontal vent terminal location - Observe the following limitations on the vent terminal location (also see Fig 6.11a - d):
• Direct exhaust installations (installations using indoor combustion air) - Exhaust terminal must be at least 4 feet below or
4 feet horizontally from any window, door, or gravity air inlet into the building.
• Direct vent installations – Exhaust elbow or coaxial terminal must be at least 1 foot from any door, window, or gravity
inlet into the building.
• Direct vent installations using termination elbows – Maintain the correct clearance and orientation between the inlet and
exhaust elbows. The elbows must be at the same level and their center lines must be between 12 and 36 inches apart.
• The bottom of the exhaust elbow, tee, or coaxial 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 exhaust elbow, tee, or coaxial terminal must be at least 7 feet above a public walkway.
• The bottom of the exhaust elbow, tee, or coaxial terminal must be at least 3 feet above any forced air inlet located within
10 feet.
• A clearance of at least 4 feet horizontally or 4 feet vertically must be maintained between the exhaust terminal and gas
meters, electric meters, regulators, and relief equipment.
• Do not locate the terminal under decks or similar structures.
• Top of exhaust elbow, tee, or coaxial terminal must be at least 4 feet below eves, softs, or overhangs. Overhang may not
exceed 3 feet (Figure 6.11d).
• Terminal must be at least 3 feet from an inside corner.
• Under certain conditions, water in the ue gas may condense on the structure in areas around the terminal. If these areas
are made of materials subject to damage by ue gas condensate, they should be protected.
• If possible, install the terminal 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.
• The noise level in the vicinity of the terminal is approximately 65 dB (roughly the level of a normal conversation). Avoid
positioning the terminal in areas where this might be objectionable.
5) Horizontal air intake terminal location - Horizontal air intake terminal must be at least 12” above the normal snow line.
6) Permitted Terminals for Vertical Venting (Vent Options 6 - 10) - Terminals used on these systems are caps. Vent
manufacturer part numbers for these caps are shown in Table 4. When Heat Fab Saf-T Vent SC is used, the 5300CI or
5400CI tting is used between the highest piece of Saf-T Vent CI and the cap. These ttings physically adapt from the
CI pipe to the cap and also provide ventilation openings which must remain open for the Saf-T Vent CI to maintain its
clearance rating.
Vertical direct vent systems (Vent Options 6 - 8) can have combustion air obtained from either a vertical or horizontal air
intake system. When combustion air is obtained from the roof, the air inlet terminal consists of a 180 degree elbow (or two
90 degree elbows) with a rodent screen as shown in Figure 6.4. When combustion air is obtained through a horizontal vent
system, the air inlet termination is a 90 degree elbow with a rodent screen as shown in Figure 6.2a.
7) Permitted terminals for Vertical Coaxial Venting (Options 11 - 13) - When the Crown vertical coaxial vent kit is used (Vent
Option 11), a cap compatible with the vent system is used (Figure 6.6, Table 6.8). The concentric air intake hood supplied in
the Crown kit is the air inlet terminal (Figure 6.6).
When vertical coaxial venting is done using Heat Fab Saf-T Vent SC (Options 12, 13), the vent terminal is a SC03VT or
SC04VT terminal installed with a 5300CI or 5400CI adaptor. The openings in this adaptor are used for combustion air.

17
17
TABLE 6.1b: SUMMARY OF VERTICAL VENTING OPTIONS
VENT OPTION # 67 8 9 10
CLASSIFICATION USED IN THIS
MANUAL
VERTICAL
DIRECT VENT
VERTICAL
DIRECT VENT
(RESERVED
FOR FUTURE
USE)
VERTICAL
DIRECT
EXHAUST
VERTICAL
DIRECT
EXHAUST
ILLUSTRATED IN FIGURE 6.4 6.4 6.5 6.5
VENT PIPE STRUCTURE
PENETRATION ROOF ROOF ROOF ROOF
AIR INTAKE PIPE STRUCTURE
PENETRATION ROOF OR WALL ROOF OR WALL N.A. N.A.
VENT PIPE SIZE 3” 4” 3” 4”
AIR INTAKE PIPE SIZE 4” 4” N.A. N.A.
MAXIMUM VENT
PIPE LENGTH
CWD060 - CWD138 47 FT 47 FT 47 FT 47 FT
CWD165 27 FT 47 FT 27 FT 47 FT
CWD193 17 FT 47 FT 17 FT 47 FT
CWD220 N.R. 47 FT N.R. 47 FT
CWD245 N.R. 47 FT N.R. 47 FT
MAXIMUM
INTAKE PIPE
LENGTH
CWD060 - CWD138 52 FT 50 FT N.A. N.A.
CWD165 32 FT 50 FT N.A. N.A.
CWD193 22 FT 50 FT N.A. N.A.
CWD220 N.R. 50 FT N.A. N.A.
CWD245 N.R. 50 FT N.A. N.A.
EXHAUST TERMINAL BY VENT SYSTEM MANUFACTURER. SAME DIAMETER AS VENT SYSTEM. SEE TABLE 4.
AIR INTAKE TERMINAL
(ROOF PENETRATION) 4” 180 ELBOW 4” 180 ELBOW N.A. N.A.
AIR INTAKE TERMINAL
(WALL PENETRATION) 4” 90 ELBOW 4” 90 ELBOW N.A. N.A.
VENT MATERIAL APPROVED VENT SYSTEM SHOWN IN TABLE 6.8
AIR INTAKE MATERIAL GALVANIZED OR PVC N.A. N.A.
“N.R” - Not recommended “N.A.” - Not applicable
8) Vertical Vent Terminal Locations (Vent Options 6 - 13) - Observe the following limitations on the location of all vertical
vent terminals (see Figs. 6.4, 6.5, 6.6, 6.7):
• The lowest discharge opening on the cap must be at least 2 feet above any object located within 10 feet.
• If outside air is used for combustion (Options 6-7, 11-13), the vertical distance between 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.
9) Terminal offsets - Horizontal elbow or tee terminals may be offset by as much as 5 ft as shown in Figure 6.10. This
sometimes helps maintain the 12” minimum clearance required above the snow line. The extra two elbows and the section
of vertical pipe on the outside of the building must be counted when checking that the maximum vent / intake pipe length is
not exceeded. On horizontal direct vent systems, both terminals must be offset by the same amount so that their relationship
to one another is the same as shown in Figure 6.2a. When this offset is used, the horizontal section of vent pipe must be
pitched away from the outside so that condensate cannot collect in the lower offset elbow.
10) Wall thimbles – Wall thimbles are required where the vent pipe passes through combustible walls with less than the
required clearance shown in Table 4.2 or as required by local codes. Vent manufacturer’s wall thimble part numbers are
shown in Table 6.8.
11) Condensate Traps and Pitch of Horizontal piping – All horizontal vent piping must be pitched ¼” per foot so that any
condensate which forms in this piping will run towards either the outdoors or into a condensate trap. Vent manufacturer’s
part numbers for suitable condensate traps are shown in Table 6.8.
All vertical vent systems must include at least one condensate trap as shown in Figures 6.4-6.7. This will collect any
condensate that forms in the vent system as well as any rain water that gets around the vent cap.
The maximum allowable vertical run directly off of the boiler without a condensate trap is 7.5 ft (Figure 6.12). Install a
condensate trap in longer vertical runs so that condensate which might form in this rst vertical section will not run into the
boiler fan.

18
18
FIGURE 6.4: VERTICAL NON-COAXIAL DIRECT VENT SYSTEM (VENT OPTIONS 6, 7)
FIGURE 6.5: VERTICAL DIRECT EXHAUST SYSTEM (VENT OPTIONS 9, 10)