Westinghouse 220VWH, 299VWH, 301VWH, 399VWH User Manual

Installation

Start-Up

Maintenance

Parts

Warranty

WBRE**220 / 299 / 301 / 399 VWH Models

Premier

Volume Water Heaters

** “NG” Denotes Natural Gas Operation

“LP” Denotes Propane Gas Operation

“VWH” Denotes Hot Water Supply Boiler

This manual must only be used by a qualied installer / service technician. Read all instructions in this manual before installing. Perform steps in the given order. Failure to do so could result in substantial property damage, severe personal injury, or death.

Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property damage, severe personal injury, or death.

California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Westinghouse reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.

The surfaces of these products contacted by potable (consumable) water contain less than 0.25% lead by weight as required by the Safe Drinking Water Act, Section 1417.

Heat Exchanger Bears the ASME “H” Stamp

NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

WARNING: If the information in these instructions is not followed exactly, a re or explosion may result causing property damage, personal injury or death.

• Do not store or use gasoline or other ammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the re department.

• Installation and service must be provided by a qualied installer, service agency or the gas supplier.

Improper installation, adjustment, alteration, service, or maintenance can cause injury, property damage, or death. Refer to this manual. Installation and service must be performed by a qualied installer, service agency, or gas supplier.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

The following dened terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important product information.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in serious personal injury or death.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in personal injury or death.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor personal injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE is used to address practices not related to personal injury.

Foreword

This manual is intended to be used in conjunction with other literature provided with the boiler. This includes all related control information. It is important that this manual, all other documents included in this system, and additional publications including the

Code for the Installation of Heat Producing Appliances and National Fuel Gas Code - ANSI Z223.1 (latest versions), be reviewed in their

entirety before beginning any work.

Installation should be made in accordance with the regulations of the Authority Having Jurisdiction, local code authorities, and utility

companies which pertain to this type of water heating equipment.

Authority Having Jurisdiction (AHJ) – The AHJ may be a federal, state, local government, or individual such as a re chief, re marshal, chief of a re prevention bureau, labor department or health department, building ocial or electrical inspector, or others having statutory authority. In some circumstances, the property owner or his/her agent assumes the role, and at government installations, the commanding ocer or departmental ocial may be the AHJ.

NOTE: Westinghouse reserves the right to modify product technical specications and components without prior notice.

For the Installer

This boiler must be installed by qualied and licensed personnel. The installer should be guided by the instructions furnished with the boiler, and by local codes and utility company requirements. In the absence of local codes, preference should be given to the National Fuel Gas Code - ANSI Z223.1, latest version.

Installations Must Comply With:

Local, state, provincial, and national codes, laws, regulations, and ordinances.

The latest version of the National Fuel Gas Code, ANSI Z223.1, from American Gas Association Laboratories, 8501 East Pleasant Valley Road, Cleveland, OH 44131.

In Canada - CGA No. B149 (latest version), from Canadian Gas Association Laboratories, 55 Scarsdale Road, Don Mills, Ontario, Canada M3B 2R3. Also, Canadian Electrical Code, C 22.1, from Canadian Standards Association, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6.

Code for the Installation of Heat Producing Appliances (latest version) from American Insurance Association, 85 John Street, New York, NY

11038.

The latest version of the National Electrical Code, NFPA No. 70.

NOTE: The gas manifold and controls met safe lighting and other performance criteria when undergoing tests specied in ANSI Z21.13

- latest edition.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

The CSD-1 ASME Code, Section CW-400 requires that hot water heating and supply boilers have a) a UL 353 temperature control device, b) at least one (1) temperature-actuated control to shut o the fuel supply when system water reaches a preset operating temperature, c) a high temperature limit control that prevents the water temperature from exceeding the maximum allowable temperature by causing a safety shutdown and lockout, and d) its own sensing element and operating switch. The temperature control system integrated into the 926 control provided with this heating appliance complies with the requirements of CSD-1 Section CW-400 as a temperature operation control. The control monitors the temperature dierence between the inlet and the outlet sensor, which is aected by boiler water ow. If this temperature dierence exceeds 55°F (typically because of low water ow or very low heat load), the control will reduce the maximum fan speed. If the temperature dierence exceeds 60°F, the control will eectively sense there is little or no water ow or heat load and shut the boiler down. The controller will restart automatically once the temperature dierence has dropped below 55°F and the minimum o time (anti-cycle time) has expired. In addition, if the control senses that the outlet water temperature has reached 210°F, the boiler is put into a hard lockout and requires manual reset to restart.

Table of Contents

Part 1 - General Safety Information 5

A. Improper Combustion 5 B. Gas 5 C. When Servicing the Water Heating System 5 D. Boiler Water 5 E. Freeze Protection 5 F. Water Temperature Adjustment 6 G. High Elevation Installations 6

Part 2 - Before You Start 7

A. What’s in the Box 8 B. How the Boiler Operates 8 C. Optional Equipment 8

Part 3 - Prepare the Boiler 9

A. Locating the Boiler 9 B. Flooring 10 C. Leveling 10 D. Clearances for Service Access 10 E. Residential Garage and Closet Installations 10 F. Exhaust Vent and Intake Pipe 11

1. Direct Vent of Exhaust and Intake 11

2. Power Venting, Indoor Combustion Air in Conned or

Unconned Space 11 G. Carbon Monoxide Detectors 12 H. Prevent Combustion Air Contamination 12 I. Removing a Boiler from a Common Vent System 12 J. Water Chemistry Requirements* 13

Part 4 - Piping 16

A. General Plumbing Information 16 B. Relief Valve 16 C. Backow Preventer 16 D. Potable Expansion Tank 16 E. Circulators 17 F. Flow Switch Installation 17 G. Scalding 18 H. High Velocity Circulator Pump 18 I. Plumbing 20 J. Applications 21

Part 5 - Venting and Condensate Removal 23

A. General 23 B. Approved Materials for Exhaust Vent and Intake Pipe 24 C. Additional Requirements for Installation in Canada 24

D. Exhaust Vent and Intake Pipe Location 25 E. Exhaust Vent and Intake Pipe Sizing 26 F. Longer Vent Runs 26 G. Exhaust Vent and Intake Pipe Installation 26 H. Applications 27

1. Direct Vent Installation of Exhaust and Intake 27

2. Venting Through an Existing System 29

3. Power Venting, Indoor Combustion Air in Conned or Unconned Space 30

I. Condensate Removal System 32

Part 6 - Wiring 33

A. Installation Must Comply With 33 B. Field Wiring Terminations 33 C. Field Wiring 33 D. Line Voltage Wiring for Standard Boiler 33 E. Alarm Connections 33 F. Low Voltage Connections for Standard Boiler 33 G. Tank Sensor or Mechanical Control 33 H. System / Pipe Sensor 34 I. Optional 0-10 Volt Building Control Signal 34 J. Optional UL353 Low Water Cut-O Interface Kit 34 K. Wiring of Cascade System Communication Bus 34 L. Cascade Master Pump and Sensor Wiring 35 M. Cascade Follower Pump and Sensor Wiring 35 N. Variable Speed Pumping 35

Part 7 - Gas Connections 38

A. Gas Piping 38 B. Check Inlet Gas Pressure 39 C. Boiler Gas Valve 40

Part 8 - Start-Up Preparation 41

A. Check / Control Water Chemistry 41 B. Check for Gas Leaks 41 C. Condensate Removal 41 D. Final Checks Before Starting Boiler 41 E. Setting Up a Single Boiler 42 F. Setting Up a Cascaded System 42 G. Lockout Condition 42 H. Cascade System Programming 42

Part 9 - Start-Up Procedure 43

A. Control Overview 43 B. Navigation of the Display 43 C. Operating Instructions 44 D. Programming Boiler Settings 44 E. Programming the System Setting 45 F. System Setting Program Navigation 45 G. Resetting the Maintenance Schedule 47

Part 10 - Start-Up Procedures for the Installer 47

A. Boiler Control Status Menu 47 B. Cascade Menu 50 C. Boiler Test Mode 51

Part 11 - Troubleshooting 51

A. Boiler Error and Fault Codes 51 B. Boiler Error 51 C. Boiler Fault 51 D. User Interface Display 52

Part 12 - Maintenance 57

A. Procedures 57 B. Combustion Chamber Coil Cleaning Instructions 57 C. Cleaning Water Side of Heat Exchanger 58 D. Maintaining the Condensate System 58

Part 13 - Installation Checklist 64 Part 14 - Maintenance Report 64

Limited Warranty 66 Maintenance Notes 68 Customer Installation Record Form 69

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

Part 1 - General Safety Information

This boiler is approved for indoor installations only and is not intended for use as a pool heater. Clearance to combustible materials: 0” top, bottom, sides, and back. Left side has all boiler mechanical connections. Boiler must have room for service: 24” front is minimum recommended service clearance. (A combustible door or removable panel is acceptable front clearance.) This boiler has been approved for closet installation and installation on combustible ooring. Do not install directly on carpeting. Install the boiler in a location where temperature and pressure relief valve discharge or a leak will not result in damage to the surrounding area. If such a location is not available, install an auxiliary catch pan. Use only Category IV vent systems.

Installer - Read all instructions in this manual before installing. Perform steps in the given order.

User - This manual is for use only by a qualied heating installer / service technician. Have this boiler serviced / inspected annually by a qualied service technician.

FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

NOTE: If the boiler is exposed to the following, do not operate.

Immediately call a qualied service technician.

1. Fire

2. Damage

3. Water Failure to follow this information could result in property damage, severe personal injury, or death.

DO NOT USE THIS BOILER IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualied service technician. The

boiler MUST BE replaced if it has been submerged. Attempting to operate a boiler that has been submerged could create numerous harmful conditions, such as a potential gas leakage causing a re and/or explosion, or the release of mold, bacteria, or other harmful particulates into the air. Operating a previously submerged boiler could result in property damage, severe personal injury, or death. NOTE: Boiler damage due to ood or submersion is considered an Act of God, and IS NOT covered under product warranty.

NOTE: Obey all local codes. Obtain all applicable permits before installing the boiler.

NOTE: Install all system components and piping in such a manner that does not reduce the performance of any re rated assembly.

This boiler has been designed to heat potable water ONLY. Using this boiler to heat non-potable uid WILL VOID product warranty, and could result in property damage, personal injury, or death.

Altering any Westinghouse boiler with parts not manufactured by Westinghouse WILL INSTANTLY VOID the boiler warranty and could result in property damage, personal injury, or death.

High heat sources (sources generating heat 100oF / 37oC or greater, such as stove pipes, space heaters, etc.) may damage plastic components of the boiler as well as plastic vent pipe materials. Such damages ARE NOT covered by warranty. It is recommended to keep a minimum clearance of 8” from high heat sources. Observe heat source manufacturer instructions, as well as local, state, provincial, and national codes, laws, regulations and ordinances when installing this boiler and related components near high heat sources.

A. Improper Combustion

Do not obstruct the ow of combustion and ventilating air. Adequate air is necessary for safe operation. Failure to keep the exhaust vent and combustion air intake clear of ice, snow, or other debris could result in property damage, serious personal injury, or death.

B. Gas

Should overheating or gas supply fail to shut o, turn o the manual gas control valve to the boiler.

C. When Servicing the Water Heating System

Be sure to disconnect electrical power before opening boiler cabinet or performing service. Failure to do so could result in electrical shock, property damage, serious personal injury, or death.

To avoid electric shock, disconnect electrical supply before performing maintenance.

NOTE: When inquiring about service or troubleshooting, reference the model and serial numbers from the boiler rating label.

To avoid severe burns, allow boiler and associated equipment to cool before servicing.

D. Boiler Water

Do not use petroleum-based cleaning or sealing compounds in a water heating system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.

Do not use “homemade cures” or “patent medicines”. Damage to the boiler, substantial property damage, and/or serious personal injury may result.

E. Freeze Protection

NOTE: Consider piping and installation when determining boiler

location.

Failure of the boiler due to freeze related damage IS NOT covered by product warranty.

Do not use this boiler for anything other than its intended purpose (as described in this manual). Doing so could result in property damage and WILL VOID product warranty.

NEVER use any toxic chemical, including automotive, standard glycol antifreeze, or ethylene glycol made for hydronic (non-potable) systems. These chemicals can attack gaskets and seals in water systems, are poisonous if consumed, and can cause personal injury or death.

UNCRATING THE BOILER - Any claims for damage or shortage in shipment must be led immediately against the transportation company by the consignee.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

F. Water Temperature Adjustment

If the boiler is going to have a set temperature above 120oF, you must use an ASSE 1017 rated mixing valve to avoid severe burns or death from scalding temperatures.

Households with small children, disabled, or elderly persons may require a 120oF or lower temperature setting to prevent severe personal injury or death due to scalding.

Approximate Time / Temperature Relationships in Scalds

120oF

125oF

130oF

135oF

140oF

145oF

150oF

155oF

Table 1 - Approximate Time / Temperature Relationships in Scalds

More than 5 minutes

1 1/2 to 2 minutes

About 30 seconds

About 10 seconds

Less than 5 seconds

Less than 3 seconds

About 1 1/2 seconds

About 1 second

G. High Elevation Installations

Natural gas at high elevation might contain less heating value than typical 1,000 BTU/cu ft and therefore can cause improper air / gas mix leading to improper combustion. For natural gas installations above 3,000 ft, call your gas provider to determine the heating value of the supplied natural gas.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

Part 2 - Before You Start

CAUTION

These VWH units must be connected to a storage tank. You must not have a direct connection of the potable water system into the heat exchanger. This could cause ow issues, short cycling, and an increase of mineral build-up in the unit. This system is designed to have incoming potable water ow through the storage tank rst, then through the heat exchanger. Failure to connect the VWH boiler to a storage tank of the minimum size requirements (80 gallons for these VWH models) will result in property damage and/or premature boiler failure. Damages resulting from incorrect installation or from use of products not approved by Westinghouse ARE NOT covered by warranty.

220VWH 299VWH / 301VWH 399VWH

First

Hour

∆T

(Delta T)

(oF)

100

110

120

130

140

Table 2 - VWH Ratings with Storage Tanks - NOTE: Gallons Per Hour Does Not Take a Storage Tank into Account

Min Tank Size (Gal.) = Required Flow (GPM) X 10

Gallons

Per Hour

635 397 414 438 866 529 546 570 1152 693 709 733

508 406 427 457 693 538 559 589 922 701 722 752

424 415 440 476 578 547 572 608 768 710 735 771

363 423 452 494 495 555 584 626 658 718 748 790

318 432 465 513 433 564 597 645 576 727 760 808

282 440 478 532 385 572 610 664 512 736 773 827

254 449 491 551 347 581 623 683 461 744 786 846

231 457 503 569 315 589 635 701 419 753 799 865

212 466 516 588 289 598 648 720 384 761 811 883

196 475 529 607 267 607 661 739 355 770 824 902

182 483 542 626 248 615 674 758 329 778 837 921

Rating

Gallon

Tank

Contact for Available

First

Hour

Rating

119

Gallon

Tank

Storage Tanks

First

Hour

Rating

175

Gallon

Tank

Gallons

Per

Hour

First

Hour

Rating

Gallon

Tank

Contact for Available

First

Hour

Rating

119

Gallon

Tank

Storage Tanks

First

Hour

Rating

175

Gallon

Tank

Gallons

Per Hour

First

Hour

Rating

Gallon

Tank

Contact for Available

First

Hour

Rating

119

Gallon

Tank

Storage Tanks

First

Hour

Rating

175

Gallon

Tank

Mixing Factor (Mf) = VWH Outlet Temp - Inlet Temp 70

First Hour Rating = Total VWH Output X VWH Eciency + .75 X Total Storage X M [ (VWH Outlet Temp - Inlet Temp) X 8.31

Example: 2 220VWH Boilers - Total Output = 440,000 BTU @ 96% Eciency VWH Outlet Temp = 140oF - Inlet Temp = 40oF 2 Storage Tanks (80 Gallons Each) =Total Storage = 160 Gallons

Mixing Factor (Mf) = 140 - 40 70

First Hour Rating = 440,000 X .96 + .75 X 160 X 1.43 [(140 - 40) X 8.31

First Hour Rating = 422,400 + 120 X 1.43 [ 831

First Hour Rating = [508 + 120

First Hour Rating = 628 X 1.43

First Hour Rating = 898 Gallons

]

X 1.43

= 1.43

]

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

Remove all sides of the shipping crate of the boiler.

A. What’s in the Box

Components (and Part #) included with the boiler:

• Temperature and Pressure Gauge (7250P-499)

• Pressure Relief Valve (7450P-254)

• Intake PVC Tee with Screens

• Exhaust PVC Coupling with Screens

• Outlet Combination Fitting (220 Model - 7450P-235, 299/301 Models - 7450P-236, 399 Model - 7450P-237)

• Flow Switch and Paddles (7250P-517)

• Installation Manual and Warranty

• CSD-1 Form

• H-3 Data Sheet

B. How the Boiler Operates

VWH® condensing technology intelligently delivers large amounts of hot water while maximizing eciency. Outlined below are the features of the system and how they operate:

Stainless Steel Heat Exchanger

The highly ecient stainless steel heat exchanger is designed to use the cold water return from the storage tank and extract the last bit of heat before it is exhausted.

Modulating Combustion System

The combustion system modulates the output of the burner during operation to match system demand and achieve the control set point while in operation. The set point can change by internal or external signals to enhance the overall performance of the system.

Control

The integrated control system monitors the system and regulates fan speed to control boiler output. This allows the boiler to deliver only the amount of heat energy required and nothing more. The control can regulate the output of multiple boilers through its cascade system function. The cascade system is capable of connecting up to eight boilers together in such a way that they function as one boiler system. This allows for greater turn down ratios and provides systematic control of the multiple boilers in an installation to minimize downtime and maximize eciency. The cascade system works by establishing one boiler as the master and the other connected boilers as followers. The master boiler requires a sensor to provide feedback on set point temperature in order to adjust heating input from the connected boilers. Each cascaded boiler will have its own pump to provide maximum ow and control heat exchanger ow rate.

Text Display and Operational LED Light Indicators

The display allows the user to change system parameters and monitor system outputs.

Gas Valve

Senses suction from the blower, allowing gas to ow only if powered and combustion air is owing.

All Metal Integrated Venturi

Controls air and gas ow into the burner.

Burner

The high grade stainless steel burner uses premixed air and gas to provide a wide range of ring rates.

Spark Ignition

The burner is ignited by applying high voltage through the system spark electrode. The spark from the electrode ignites mixed gas o of the burner.

Supply Water Temperature Sensor

This sensor monitors the boiler outlet water temperature (System Supply). The control adjusts boiler ring rate so the supply temperature will match the boiler set point.

Return Water Temperature Sensor This sensor monitors boiler return water temperature (System Return). Flue Sensor

Monitors ue temperature and adjusts ring rate.

Temperature and Pressure Gauge

Allows the user to monitor system temperature and pressure.

Electrical eld connections with terminal strips

The electrical cover allows easy access to the clearly marked line voltage and low voltage terminal strips to facilitate wiring the boiler.

Condensate Collection System

This boiler is a high eciency appliance and will produce condensate. The condensate collection system has a oat which monitors condensate level and prevents condensate from backing up into the combustion system. Inside the collection system is a built in trap which seals the combustion system from the connected drain. This condensate should be neutralized to avoid damage to the drainage system or piping.

Flow Protection

The supplied ow switch is designed to protect the boiler during low ow conditions. The boiler control also monitors ow through the heat exchanger by monitoring the return and supply sensors and will shut down the burner before overheating occurs.

0-10 Volt Input

Allows the installer to connect a BMS (Building Management System) to control the boiler.

Condensate Flue Check System

The check system prevents heat exchanger exhaust from backing up into the cabinet.

Pump Service Mode

Allows manual operation of pumps to commission system and check pump operation.

C. Optional Equipment

Optional equipment available from Westinghouse (and Part #):

• Wall Mount Bracket (7450P-211)

• System Sensor (7250P-324)

• Indirect Tank Sensor (7250P-325)

• 3” Stainless Steel Vent Termination Kit (V1000)

• 4” Stainless Steel Vent Termination Kit (V2000)

• 6” Stainless Steel Vent Termination Kit (V3000)

• 2” PVC Concentric Vent Kit (KGAVT0501CVT)

• 3” PVC Concentric Vent Kit (KGAVT0601CVT)

• 3” Polypro Vent Kit (8400P-001)

• 3” Polypro Pipe

(33’ length # 8400P-002, 49.5’ length # 8400P-003)

• Low Water Cut-O Kit (7450P-904)

• Manual Reset High Limit (7450P-910)

• Alarm System (to monitor any failure) (7350P-602)

• 928 PC Connection Kit with Software (7450P-330)

• Condensate Neutralizer (220/299/301 Models - 7450P-212, 399 Model - 7350P-611)

• Eighty Gallon Glass-Lined Storage Tank (GL-80)

• Eighty Gallon Stainless Steel Storage Tank (SSU-80CB)

VWH Circulator Kits

• 220 Model - Part # 7450P-248

• 299 / 301 Models - Part # 7450P-249

• 399 Model - Part # 7450P-250

NOTE: When using an optional system sensor, pipe insulation must be wrapped around it to improve temperature measurement accuracy and increase overall system eciency.

Part 3 - Prepare the Boiler

Remove all sides of the shipping crate to allow the boiler to be moved into its installation location. The boiler is also equipped with leveling feet that can be used to level the boiler properly on an uneven location surface. If surface ooring is rough, take care when moving the boiler into position, as catching the leveling feet could damage the boiler.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

COLD WEATHER HANDLING - If the boiler has been stored in a very cold location (BELOW 0oF) before installation, handle with care until the components come to room temperature. Failure to do so could result in damage to the boiler.

Carefully consider installation when determining boiler location. Please read the entire manual before attempting installation. Failure to properly take factors such as boiler venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.

A. Locating the Boiler

This boiler is certied for indoor use only. DO NOT INSTALL OUTDOORS. Outdoor installations ARE NOT covered by warranty. Failure to install the boiler indoors could result in property damage, severe personal injury, or death.

Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk. Ensure that the installation location adheres to the information included in this manual. Failure to do so could result in property damage, serious personal injury, or death. Failure of boiler or components due to incorrect operating conditions IS NOT covered by product warranty.

This boiler must be installed upright in the vertical position as described in this manual. DO NOT attempt to install this boiler in any other orientation. Doing so will result in improper boiler operation and property damage, and could result in serious personal injury or death.

1. Installation Area (Mechanical Room) Operating Conditions

• Ensure ambient temperatures are higher than 32oF / 0oC and lower than 104oF / 40oC

• Prevent the air from becoming contaminated by the products, places, and conditions listed in this manual

• Avoid continuously high levels of humidity

• Never close existing ventilation openings

• Ensure a minimum 1” clearance around hot water and exhaust vent pipes

• NOTE: To prevent condensing in the fan, it is recommended to avoid prolonged exposure to temperatures below 45oF

This boiler has a condensate disposal system that may freeze if exposed to sustained temperatures below 32oF. Precautions should be taken to protect the condensate trap and drain lines from sustained freezing conditions. Failure to take precautions could result in property damage, severe personal injury, or death.

2. Check for nearby connections to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

• Condensate drain

3. Check area around boiler. Remove any combustible materials, gasoline, and other ammable liquids.

Failure to keep the boiler area clear and free of combustible materials, liquids, and vapors can result in substantial property damage, severe personal injury, or death.

The service life of the boiler’s exposed metallic surfaces, such as the casing, as well as internal surfaces, such as the heat exchanger, are directly inuenced by proximity to damp and salty marine environments. In such areas higher concentration levels of chlorides from sea spray coupled with relative humidity can lead to degradation of boiler components. In these environments, boilers must not be installed using direct vent systems which draw outdoor air for combustion. Such boilers must be installed using room air for combustion. Indoor air will have a much lower relative humidity, and hence potential corrosion will be minimized.

High heat sources (generating heat 100oF / 37oC or greater, such as boiler ue pipes, space heaters, etc.) may damage plastic components of the boiler as well as plastic vent pipe materials. Such damages ARE NOT covered by warranty. It is recommended to keep a minimum clearance of 8” from high heat sources. Observe heat source manufacturer instructions, as well as local, state, provincial, and national codes, laws, regulations, and ordinances when installing this boiler and related components near high heat sources.

Locate the boiler where any leakage from the relief valve, related piping, tank, or connections will not result in damage to surrounding areas or lower oors of the building. The boiler should be located near a oor drain or installed in a drain pan. Leakage damages ARE NOT covered by warranty.

Failure of the boiler or components due to incorrect operating conditions IS NOT covered by product warranty.

4. Gas control system components must be protected from dripping water during operation and service.

5. If the boiler is to replace an existing boiler, check for and correct any existing system problems, such as:

• System leaks

• Location that could cause the system and boiler to freeze and leak

• Incorrectly sized expansion tank

6. Clean and ush system when reinstalling a boiler.

NOTE: When installing in a zero clearance location, it may not be possible to read or view some product labeling. It is recommended to make note of the boiler model and serial number.

Do not mount the boiler to a hollow wall. Mount to the studs only.

Use extreme care not to drop the boiler or cause bodily injury while lifting or mounting the boiler onto the optional wall mount bracket.

Gas conversion should be performed BEFORE the boiler is installed. Carefully follow the gas conversion instructions when performing the conversion.

Failure to follow these instructions could result in property damage, severe personal injury, or death.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

CORRECT

INCORRECT

B. Flooring

Ensure that the oor and structure of the installation location are sucient to support the full installed weight of the boiler, including water content of the heat exchanger and related piping. Failure to ensure the oor and structure of the installation location are structurally sound before installation of the boiler can result in structural failure, substantial property damage, severe personal injury, or death.

This boiler is approved for installation on combustible ooring, but must never be installed on carpeting. Installing this boiler on carpeting could result in re, property damage, severe personal injury, or death.

C. Leveling

In order for the condensate to properly ow out of the collection system, the area where you locate the boiler must be level. Location must also fully support the weight of the lled boiler.

NOTE: A combustible door or removable panel is acceptable front clearance.

Minimum Clearances from Combustible Materials

• Hot water pipes - at least 1” from combustible materials

• Exhaust vent pipe - at least 1” from combustible materials

The space must be provided with combustion / ventilation air openings correctly sized for all other appliances located in the same space as the boiler. The boiler cover must be securely fastened to prevent the boiler from drawing air from the boiler room. This is particularly important if the boiler is in a room with other appliances. Failure to comply with the above warnings could result in substantial property damage, severe personal injury, or death.

All boilers eventually leak. It is recommended to install a catch pan beneath the boiler. This catch pan should be sized with a maximum depth of 2”, and a minimum diameter 2” greater than the diameter of the boiler. The catch pan should empty into an open drain line. This drain line should be 3/4” ID minimum, piped to an open drain. Failure to follow these instructions could result in property damage. Such damages ARE NOT covered by product warranty.

Figure 1 - Correct and Incorrect Leveling

D. Clearances for Service Access

E. Residential Garage and Closet Installations

Check with your local Authority Having Jurisdiction for requirements when installing the boiler in a garage or closet. Please read the entire manual before attempting installation. Failure to properly take factors such as venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.

Precautions

If the boiler is located in a residential garage, per ANSI Z223.1:

• Install the boiler burner and ignition devices a minimum of 18” above the oor of the garage. This will ensure the burner and ignition devices are well o the oor.

• When raising the boiler ensure the entire bottom and fully lled weight of the boiler are fully supported.

• Locate or protect the boiler so it cannot be damaged by a moving vehicle.

The space must be provided with correctly sized combustion/ ventilation air openings for all other appliances located in the space with the boiler. For power venting installations using room air for combustion, refer to the venting section, this manual, for descriptions of conned and unconned spaces. Do not install the boiler in an attic. Failure to comply with these warnings could result in substantial property damage, severe personal injury, or death.

Figure 2 - Recommended Service Clearances

NOTE: If you do not provide the minimum clearances shown in Figure

2 it might not be possible to service the boiler without removing it from the space.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

F. Exhaust Vent and Intake Pipe

The boiler is rated ANSI Z21.13 Category IV (pressurized vent, likely to form condensate in the vent) and requires a special vent system designed for pressurized venting.

NOTE: The venting options described here (and further detailed in the Venting section, this manual) are the lone venting options approved for this boiler. Failure to vent the boiler in accordance with the provided venting instructions will void the warranty.

Failure to vent the boiler properly will result in serious personal injury or death.

to supply sucient combustion air based on the boiler input. Never obstruct the supply of combustion air to the boiler. If the boiler is installed in areas where indoor air is contaminated (see Table 3) it is imperative that the boiler be installed as direct vent so that all combustion air is taken directly from the outdoors into the boiler intake connection. Unconned space is space with volume greater than 50 cubic feet per 1,000 BTU/hr (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space through openings not furnished with doors are considered part of the space. See Venting Section for details. Conned space is space with volume less than 50 cubic feet per 1,000 BTU/hr (4.8 cubic meters per kW) of the total input rating of all fuel-burning appliances installed in that space. Rooms connected directly to this space through openings not furnished with doors are considered part of the space. When drawing combustion air from inside a conventionally constructed building to a conned space, such space should be provided with two permanent openings: one located 6” (15 cm) below the space ceiling, the other 6” (15cm) above the space oor. Each opening should have a free area of one square inch per 1,000 BTU/hr (22cm2/kW) of the total input of all appliances in the space, but not less than 100 square inches (645cm2). If the conned space is within a building of tight construction, air for combustion must be obtained from the outdoors as outlined in the Venting section of this manual.

Do not attempt to vent this boiler by any means other than those described in this manual. Doing so will void the warranty and may result in severe personal injury or death.

The exhaust discharged by this boiler may be very hot. Avoid touching or other direct contact with the exhaust gases of the vent termination assembly. Doing so could result in severe personal injury or death.

Vents must be properly supported. Boiler exhaust and intake connections are not designed to carry heavy weight. Vent support brackets must be within 1’ of the boiler and the balance at 4’ intervals. Boiler must be readily accessible for visual inspection for rst 3’ from the boiler. Failure to properly support vents could result in property damage, severe personal injury, or death.

1. Direct Vent of Exhaust and Intake

If installing a direct vent option, combustion air must be drawn from the outdoors directly into the boiler intake and exhaust must terminate outdoors. There are three basic direct vent options detailed in this manual: 1. Side Wall Venting, 2. Roof Venting, and 3. Unbalanced Venting. Be sure to locate the boiler such that the exhaust vent and intake piping can be routed through the building and properly terminated. Dierent vent terminals can be used to simplify and eliminate multiple penetrations in the building structure (see Optional Equipment in Venting Section). The exhaust vent and intake piping lengths, routing, and termination methods must all comply with the methods and limits given in the Venting Section, this manual. When installing a combustion air intake from outdoors, care must be taken to utilize uncontaminated combustion air. To prevent

combustion air contamination, see Table 3.

2. Power Venting, Indoor Combustion Air in Conned or Unconned Space

This boiler requires fresh, uncontaminated air for safe operation and must be installed in a mechanical room where there is adequate combustion and ventilating air. NOTE: To prevent combustion air contamination, see Table 3. Combustion air from the indoor space can be used if the space has adequate area or when air is provided through a duct or louver

When drawing combustion air from the outside into the mechanical room, care must be taken to provide adequate freeze protection.

Failure to provide an adequate supply of fresh combustion air can cause poisonous ue gases to enter the living space, resulting in severe personal injury or death. To prevent combustion air contamination, see Table 3.

G. Carbon Monoxide Detectors

In the Commonwealth of Massachusetts and As Required by State and Local Codes:

Installation of Carbon Monoxide Detectors: At the time of installation or replacement of the vented gas fueled appliance, the installing plumber or gas tter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the oor level where the gas appliance is installed, unless the appliance is located in a detached, uninhabitable structure separate from the dwelling, building, or structure used in whole or in part for residential purposes. In addition, the installing plumber or gas tter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on each additional level of the dwelling, building, or structure served by the vented gas appliance. It shall be the responsibility of the property owner to secure the service of qualied licensed professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the vented gas fueled appliance is installed in a crawl space or attic, the hard wired carbon monoxide detector with alarm and battery back-up shall be installed on the next adjacent oor level. b. In the event that these requirements cannot be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

Do not attempt to vent this appliance by any means other than those described in this manual. Doing so will void the warranty and may result in severe personal injury or death.

Approved Carbon Monoxide Detectors: Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 70 and be ANSI/UL 2034 listed and IAS certied.

H. Prevent Combustion Air Contamination

Install intake air piping for the boiler as described in the Venting Section, this manual. Do not terminate exhaust in locations that can allow contamination of intake air.

Ensure that the intake air will not contain any of the contaminants in Table 3. Contaminated air will damage the boiler, resulting in possible substantial property damage, severe personal injury, or death. For example, do not pipe intake air near a swimming pool or laundry facilities. These areas always contain contaminants.

I. Removing a Boiler from a Common Vent System

Do not install the boiler into a common vent with any other appliance. This will cause ue gas spillage or appliance malfunction, resulting in possible substantial property damage, severe personal injury, or death.

Failure to follow all instructions can result in ue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Products to Avoid

Spray cans containing uorocarbons

Permanent wave solutions Swimming pools

Chlorinated waxes / cleaners Metal fabrication plants

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing Refrigeration repair shops

Sodium chloride used for water softening

Refrigerant leaks Auto body shops

Paint or varnish removers Plastic manufacturing plants

Hydrochloric or Muriatic acid

Cements and glues New building construction

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, laundry detergents, and cleaning solvents

Adhesives used to fasten building products

Table 3 - Products and Areas Likely to Have Contaminants

NOTE: DAMAGE TO THE BOILER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY. (Refer to

the limited warranty for complete terms and conditions.)

maximum speed. Do not operate a summer exhaust fan. Close all replace dampers.

4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust the thermostat so the appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the ame of a match or candle or smoke from a cigarette.

6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined, return doors, windows, exhaust fans, replace dampers, and any other gas burning appliances to their previous condition of use.

7. Any improper operation of the common venting system should be corrected to conform to the National Fuel Gas Code, ANSI Z223.1. When resizing any portion of the common venting system, the system should approach the minimum size as determined using the appropriate tables in Appendix G of ANSI Z223.1.

Areas Likely to Have

Contaminants

Dry cleaning / laundry areas and establishments

Beauty shops

Photo processing plants

Furniture renishing areas and establishments

Remodeling areas

Garages and workshops

Figure 3 - CO Warning Label

When removing an existing boiler, follow the steps below.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch to determine if there is blockage, leakage, corrosion, or other deciencies that could cause an unsafe condition.

3. If practical, close all building doors, windows, and doors between the space in which the boiler remains connected to the common venting system and other spaces in the building. Turn on clothes dryers and any appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, at

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

J. Water Chemistry Requirements*

Chemical imbalance of the water supply may aect eciency and cause severe damage to the appliance and associated equipment. Water quality must be professionally analyzed to determine whether it is necessary to treat the water. Various solutions are available to adjust water quality. Adverse water quality will aect the reliability of the system. In addition, operating temperatures above 135oF will accelerate the build-up of lime scale and possibly shorten appliance service life. Failure of an appliance due to lime scale build-up, low pH, or other chemical imbalance IS NOT covered by the warranty.

The water must be potable, free of corrosive chemicals, sand, dirt, and other contaminates. It is up to the installer to ensure the water does not contain corrosive chemicals or elements that can damage the heat exchanger. Potable water is dened as drinkable water supplied from utility or well water in compliance with EPA secondary maximum contaminant levels (40 CFR Part 143.3) as shown in the table below. If the water contains contaminants higher than outlined by the EPA, water treatment is recommended and additional, more frequent maintenance may be required.

If you suspect that your water is contaminated in any way, discontinue use of the appliance and contact an authorized technician or licensed professional.

Maximum

Contaminant

Total Hardness

(Commercial

Use - 140oF and

above water

temperature)

Aluminum 0.05 to 0.2 mg/l

Chloride 100 mg/l

Copper 1 mg/l

Iron 0.3 mg/l

Manganese 0.05 mg/l

Table 4 - Water Quality Specications

*NOTE: It is recommended to clean heat exchanger at least once

a year to prevent lime scale buildup. Follow the maintenance procedure in the Maintenance Section of this manual to clean the heat exchanger.

Allowable

Level

120 mg/l

(7 grains/gallon)

Contami-

nant

pH 6.5-8.5

Sulfate 205 mg/l

Total

Dissolved

Solids (TDS)

Zinc 5 mg/l

Dissolved

Carbon

Dioxide (CO2)

Maximum Allowable

Level

500 mg/l

15 mg/l or

PPM

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

Figure 4 - Boiler Dimensions - NOTE: All Dimensions Are Approximate - VWH in Model Number Denotes Volume Water Heater Model

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

Figure 5 - Boiler Dimensions - NOTE: All Dimensions Are Approximate - VWH in Model Number Denotes Volume Water Heater Model

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

Part 4 - Piping

Failure to follow the instructions in this section WILL VOID the warranty and may result in property damage, severe personal injury, or death.

Dielectric unions or galvanized steel ttings must not be used in a system with this boiler. Doing so WILL VOID the warranty. Use only copper, brass, or stainless steel ttings. Teon thread sealant must be used on all connections.

DO NOT pipe this boiler with black iron, galvanized steel, steel, or lead pipe. Doing so will result in premature product failure and property damage, and WILL VOID the warranty.

Plumbing of this product should only be done by a qualied, licensed plumber in accordance with all local plumbing codes. The boiler is designed to be connected to a storage tank to supply domestic hot water. Westinghouse oers 60/80/119/175 gallon size storage tanks in either stainless steel or glass-lined construction. These storage tanks will be directly connected to the boiler supply and return connection.

A. General Plumbing Information

The building piping system must meet or exceed the the piping requirements in this manual.

Use two wrenches when tightening water piping at boiler. Use one wrench to prevent the boiler return or supply line from turning. Failure to prevent piping connections from turning could cause damage to boiler components.

NOTE: The addition of a high temperature limiting device is important if the boiler is to be connected to a domestic hot water system. Connect the cold water supply to both the storage bottom port and the supply side of the boiler (shown in Applications, this manual). It is important that you install a ow check on the supply line of the boiler BEFORE connecting the feed line to the storage tank. This allows the cold feed to ow through the storage tank rst. It is recommended that you install shut o valves on the cold feed line for future ease of service. If there is a back ow preventer or any type of no return valve in the system, then you must install an additional tee for a suitable potable hot water expansion tank. Connect the storage tank return line to the return connection located on the boiler (shown in Applications, this manual). Then connect the storage tank hot water outlet to the hot water plumbing lines.

B. Relief Valve

Connect discharge piping to a safe disposal location following the guidelines below.

To avoid water damage or scalding due to relief valve operation:

• Discharge line must be connected to relief valve outlet and run to a safe place of disposal. Terminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the relief valve discharge.

• Discharge line must be as short as possible and the same size as the valve discharge connection throughout its entire length.

• Discharge line must pitch downward from the valve and terminate at least 6” above the oor drain, making discharge clearly visible.

• The discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of 375oF or greater.

• Do not pipe discharge to any location where freezing could occur.

• No valve may be installed between the relief valve and boiler or in the discharge line. Do not plug or place any obstruction in the discharge line.

• Test the operation of the relief valve after lling and pressurizing the system by lifting the lever. Make sure the valve discharges freely. If the valve fails to operate correctly, immediately replace with a new properly rated relief valve.

• Test T&P valve at least once annually to ensure the waterway is clear. If valve does not operate, turn the boiler “o” and call a plumber immediately.

• Take care whenever operating relief valve to avoid scalding injury or property damage.

FAILURE TO COMPLY WITH THE ABOVE GUIDELINES COULD RESULT IN FAILURE OF RELIEF VALVE OPERATION, RESULTING IN POSSIBILITY OF SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

Do not thread a cap or plug into the relief valve or relief valve line under any circumstances! Explosion and property damage, serious injury, or death may result.

RE-INSPECTION OF T&P RELIEF VALVES: T&P valves should be inspected AT LEAST ONCE EVERY THREE YEARS, and replaced if necessary, by a licensed plumbing contractor or qualied service

technician to ensure that the product has not been aected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occuring conditions may corrode the valve and its components over time, rendering the valve inoperative. Such conditions can only be detected if the valve and its components are physically removed and inspected. Do not attempt to conduct an inspection on your own. Contact your plumbing contractor for a re-inspection to assure continued safety.

FAILURE TO RE-INSPECT THE T&P VALVE AS DIRECTED COULD RESULT IN UNSAFE TEMPERATURE AND/OR PRESSURE BUILDUP WHICH CAN RESULT IN PROPERTY DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH.

C. Backow Preventer

Use a backow preventer specically designed for boiler installations. This valve should be installed on the cold water ll supply line per local codes.

D. Potable Expansion Tank

A potable hot water expansion tank is required to oset heated water expansion. In most city plumbing systems, the water meter has a no return or back ow device built into the system to prevent back owing of water into city mains. Some local codes require back ow preventers on all incoming water supplies. The hot water expansion tank must be listed for potable water use. The expansion tank should be located on the cold inlet piping close to the boiler.

Expansion Tank and Make-Up Water

1. Ensure that the expansion tank is sized to correctly handle boiler and system water volume and temperature.

Expansion tanks must be sized according to total system volume. This includes all length of pipe, all xtures, boilers, etc. Failure to properly size for system expansion could result in wasted time, money, possible property damage, serious injury, or death.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

Undersized expansion tanks cause system water to be lost from the relief valve, causing make-up water to be added. Eventual boiler failure can result due to excessive make-up water addition. SUCH

FAILURE IS NOT COVERED BY WARRANTY.

DO NOT install automatic air vents on closed type expansion tank

systems. Air must remain in the system and return to the tank to provide an air cushion. An automatic air vent would cause air to leave the system, resulting in improper operation of the expansion tank.

The expansion tank must be suitable for hot potable water systems.

Expansion Tank Sizing*

VWH Model Heat Exchanger Volume (Gallons)

220 2.6

299 / 301 3.1

399 3.7

Table 5 - *Add Required Storage Tank Gallon Size to Heat Exchanger Volume - 60, 80, 119, and 175 Gallon Tanks Available

2. The expansion tank must be located as shown in Applications, this manual, or following recognized design methods. See expansion tank manufacturer’s instructions for details.

E. Circulators

Every VWH system requires special attention to circulator size to overcome pressure drop through the boiler and its related piping. All circulators installed on the VWH system must be designed for potable water installations. Boiler pressure drop is detailed in this manual.

Water temperature above 140oF requires the circulator to run continuously. Water hardness must be between 5 and 7 grains. Hardness above 7 grains will damage the heat exchanger and shorten the service life of the boiler.

DO NOT use the boiler circulator in any location other than the ones shown in this manual. The boiler circulator location is selected to ensure adequate ow through the boiler. Failure to comply with this caution could result in unreliable performance and nuisance shutdowns from insucient ow.

F. Flow Switch Installation

1. Choosing the correct ow paddle. The boiler comes with a ow switch and four ow paddles. Use the table below to determine which paddle to use with the boiler.

3. Thread outlet combination tting onto supply outlet of boiler using pipe dope.

4. Thread ow switch into outlet combination tting using pipe dope,

making certain the FLOW arrow points in the correct direction.

5. Thread relief valve into outlet combination tting using pipe dope.

6. Thread temperature and pressure gauge into outlet combination tting using pipe dope.

7. Connect red wire from ow switch to boiler wire harness.

VWH Model Paddle Size

220 H1

299 / 301 H2

399 H3

N/A H4

Table 6 - Flow Paddle Sizing

2. Use a Phillips Head screwdriver to attach ow paddle as shown below.

8. When installation is complete, power up the boiler and program set point. *Please note that these illustrations are meant only

to demonstrate installation. The installer is responsible for all equipment and detailing required by local codes.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

G. Scalding

This boiler can deliver scalding water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased water temperatures. By setting the thermostat on this boiler to obtain the increased water temperature required by these appliances you may create the potential for scald injury.

To protect against injury, install a mixing valve in the water system. This valve will reduce point of use discharge temperatures by mixing cold and hot water in branch supply lines. Such valves are available from your local plumbing supplier.

Table 7 details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.

H. High Velocity Circulator Pump

Every VWH system requires special attention to pump size in order to overcome pressure drop through the boiler and its related piping. All circulators installed on the VWH system must be designed for a potable water system. In addition, the heat exchanger has a minimum total water volume that must be taken into account when sizing the circulator. Minimum ow rates are listed in the table below.

Minimum Boiler Flow Rates

VWH Model Minimum Flow (GPM)

220 14.6

299 / 301 20

399 26

Table 8 - Minimum Flow Rates

The risk of scalding increases when raising tank temperature. Use a water tempering or mixing valve when raising tank temperature to lessen the chance of scalds. Consult codes for conformance. Failure to install a temperature limiting or mixing valve and follow these instructions could result in property damage, severe personal injury, or death due to scalds.

Approximate Time / Temperature Relationships in Scalds

120oF

125oF

130oF

135oF

140oF

145oF

150oF

155oF

Table 7 - Approximate Time / Temperature Relationships in Scalds

More than 5 minutes

1 1/2 to 2 minutes

About 30 seconds

About 10 seconds

Less than 5 seconds

Less than 3 seconds

About 1 1/2 seconds

About 1 second

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

Heat Exchanger Pressure Drop

Flow Rate in GPM and Corresponding Pressure Drop in Feet (Δ P’)

Model 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

220 * * * * * * * * * 8’ 10’ 11.5’ 13’ 15’ 16.5’ 17’ 19’

299 / 301 * * * * * * * * * * * * * * 13’ 14’ 15’

399 * * * * * * * * * * * * * * * * *

Model 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

220 21’ 23’ 24’ * * * * * * * * * * * * * *

299 / 301 16.5’ 18’ 20’ 22’ 24’ 26’ 29’ 33’ 36’ * * * * * * * *

399 * * * 12.9’ 13.6’ 14’ 15.7’ 17’ 18’ 19.4’ 21’ 22.5’ 26’ 28’ 31’ 34’ 39’

Table 9 - *Do not operate the boiler at these ow rates. These low or high ow rates will damage the heat exchanger or related components. Damages due to improper operation ARE NOT covered by warranty.

The chart below represents various system design temperature rise through the boiler along with respective ows and friction loss. This is provided to aid in circulator selection.

System Temperature Rise Chart

20°Δt 25°Δt 30°Δt

Model Friction Ft Flow Rate (GPM) Friction Ft Flow Rate (GPM) Friction Ft Flow Rate (GPM)

220 19’ 22 13’ 18.3 8’ 14.6

299 / 301 29’ 29 18’ 24.5

399 39’ 39 19’ 32.5 26

Table 10 - Temperature Rise, Friction Ft and Flow Rate

13’

The chart below represents the combined ow rates and pipe sizes when using multiple boilers to design the manifold system for the primary circuit. To size, simply add up the number of boilers and the required ow rates for the system design temperature. Example: (5) 220 model boilers with a design of 20°Δt degree temperature rise with each boiler having an individual ow rate of 22 GPM. To correctly size the manifold feeding these (5) boilers you would need a pipe size of 4”.

Multiple Boiler Manifold Piping

Flow Rate (GPM) 16 22 24 30 32 33 40 44 45 48 50 55 60 66 75 80 85 88 90 100 110

Pipe Dia. (In.) 2 2 1/2 3 4

Table 11 - Multiple Boiler Manifold Piping

Flow Rate (GPM)

120 132 150 160 170 179 200 210 239 240 250 255 300 340 350 400 425 510 595 680

Pipe Dia. (In.) 4 5 6 8

Table 12 - Multiple Boiler Manifold Piping

Figure 6 - Multiple Boiler Manifold Piping

Multiple Boiler Manifold Piping

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

If you suspect that your water is contaminated in any way, discontinue use of the appliance and contact an authorized technician or licensed professional.

Maximum

Contaminant

Total Hardness

(Commercial

Use - 140oF and

above water

temperature)

Aluminum 0.05 to 0.2 mg/l

Chloride 100 mg/l

Copper 1 mg/l

Iron 0.3 mg/l

Manganese 0.05 mg/l

*NOTE: It is recommended to clean heat exchanger at least once a year to prevent lime scale buildup. Follow the maintenance procedure in the Maintenance Section of this manual to clean the heat exchanger.

Allowable

Level

120 mg/l

(7 grains/gallon)

Contami-

nant

pH 6.5-8.5

Sulfate 205 mg/l

Total

Dissolved

Solids (TDS)

Zinc 5 mg/l

Dissolved

Carbon

Dioxide (CO2)

Maximum Allowable

Level

500 mg/l

15 mg/l or

PPM

Minimum VWH Pipe Sizes

220 1” NPT

299 / 301 1 1/4” NPT

399 1 1/2” NPT

Table 13 - Minimum Pipe Sizes

I. Plumbing

The boiler is designed to function in an open loop hot water supply system. We have included a temperature and pressure gauge that allows the user to monitor the system pressure and outlet temperature from the boiler. It is important to note that the boiler has a minimal amount of pressure drop and must be calculated when sizing the circulators. Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.). Allow clearance for basic service of boiler circulator, valves and other components. Observe the minimum 1” clearance around all uninsulated hot water pipes when openings around pipes are not protected by noncombustible materials. Basic steps are listed below, with illustration that will guide you through the installation of the boiler.

1. Connect the system return marked “Boiler Return”.

2. Connect the system supply marked “Boiler Supply”.

3. Install a circulator as shown in Applications (this manual). Make sure the circulator is properly sized for the system and friction loss.

4. Install an expansion tank on the system supply. Consult the expansion tank manufacturer’s instruction manual (see Part 4, Section D for water volume) for specic information relating to expansion tank installation. Size the expansion tank for the required system volume and capacity.

5. Install a drain valve at the lowest point of the system. Note: The boiler cannot be drained completely of water without purging the unit with an air pressure of 15 PSI.

6. The relief valve and temperature and pressure gauge are included in the accessory kit. A discharge line should be installed 6” above the drain in the event of a pressure relief. The pipe size must be the same size as the relief valve outlet. NEVER BLOCK THE OUTLET OF THE

SAFETY RELIEF VALVE.

Piping Components Water Heating System Piping

System piping MUST be sized per technical pipe requirements listed in Tables 11, 12, and 13. Reducing pipe size can restrict ow rate through the boiler, causing inadvertent short cycling and poor system performance.

Check Valves

Field supplied. Check valves are recommended for installation as shown in Applications.

Isolation Valves

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted ow rate through the boiler.

Anti-Scald Mixing Valve

Field supplied. An anti-scald mixing valve is recommended when storing domestic hot water above 115°F.

Unions

Field supplied. Recommended for unit serviceability. DO NOT USE DIELECTRIC UNIONS! ONLY BRASS, COPPER, OR STAINLESS STEEL.

Pressure Relief Valve

Factory supplied on boiler. The pressure relief valve is sized to ASME specications. Storage tank may require additional relief valves depending on local codes.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

J. Applications

Figure 7 - VWH with Storage Tank

Figure 8 - Two VWH Boilers with Storage Tank

NOTES:

1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.

2. Boiler circulator must be rated for open loop application. Do not use cast-iron circulators.

3. Boiler circulator(s) operate continuously.

4. Piping to the water storage tank must be at least the size of the boiler return and supply connections.

5. See this manual for minimum pipe sizing.

6. All pumps are shown with isolation anges or full port ball valves for isolation. The alternative is standard anges with full port ball valves and a separate ow check valve.

7. Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves.

8. Install vacuum relief valve in accordance with local code requirements.

9. All multiple boilers and multiple storage tanks must be installed with reverse return piping as shown.

10. Expansion tank must be rated for use with potable water.

11. Use either indirect/tank sensor or system/pipe sensor mounted on common return to the boiler.

12. Aquastat or system/pipe sensor connects to DHW sensor input on master boiler.

An ASSE 1017 thermostatic mixing valve is recommended on all tanks if the hot water temperature leaving the tank is above 119oF. Failure to do so could result in substantial property damage, serious injury, or death.

The piping will not support the weight of the circulators. Refer to the circulator manufacturer’s instructions to properly support the circulator. Failure to comply with these instructions could result in property damage, severe personal injury, or death.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17

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Westinghouse 220VWH, 299VWH, 301VWH, 399VWH User Manual

Specifications and Main Features

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User Manual