Westinghouse 220VWH User manual

Premier
Volume Water Heaters
Installation
Start-Up
Maintenance
Parts
Warranty
WBRE**220 / 299 / 301 / 399
VWH Models
** “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.
Westinghouse reserves the right to make product changes or updates without notice and will not be held liable for
typographical errors in literature.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
WHL-053 Rev. 00 Rel. 003 Date 7.21.17
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.
Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property
damage, severe personal injury, or death.
Heat Exchanger Bears the ASME “H” Stamp
California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth
defects, or other reproductive harm.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17
2
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
3
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
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.
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.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17
4
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
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
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.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17
5
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.
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.
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.
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.
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
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.
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.
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.
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.
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.