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.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17
6
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.
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.
Approximate Time / Temperature Relationships in Scalds
120oFMore than 5 minutes
125oF1 1/2 to 2 minutes
130oFAbout 30 seconds
135oFAbout 10 seconds
140oFLess than 5 seconds
145oFLess than 3 seconds
150oFAbout 1 1/2 seconds
155oFAbout 1 second
Table 1 - Approximate Time / Temperature Relationships in Scalds
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
7
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 byWestinghouse ARE NOT covered by warranty.
∆T
(Delta T)
(oF)
220VWH 299VWH / 301VWH 399VWH
Gallons
Per Hour
First
Hour
Rating
80
Gallon
Tank
First
Hour
Rating
119
Gallon
Tank
First
Hour
Rating
175
Gallon
Tank
Gallons
Per
Hour
First
Hour
Rating
80
Gallon
Tank
First
Hour
Rating
119
Gallon
Tank
First
Hour
Rating
175
Gallon
Tank
Gallons
Per Hour
First
Hour
Rating
80
Gallon
Tank
First
Hour
Rating
119
Gallon
Tank
First
Hour
Rating
175
Gallon
Tank
Contact for Available
Storage Tanks
Contact for Available
Storage Tanks
Contact for Available
Storage Tanks
40o635 397 414 438 866 529 546 570 1152 693 709 733
50o508 406 427 457 693 538 559 589 922 701 722 752
60o424 415 440 476 578 547 572 608 768 710 735 771
70o363 423 452 494 495 555 584 626 658 718 748 790
80o318 432 465 513 433 564 597 645 576 727 760 808
90o282 440 478 532 385 572 610 664 512 736 773 827
100o254 449 491 551 347 581 623 683 461 744 786 846
110o231 457 503 569 315 589 635 701 419 753 799 865
120o212 466 516 588 289 598 648 720 384 761 811 883
130o196 475 529 607 267 607 661 739 355 770 824 902
140o182 483 542 626 248 615 674 758 329 778 837 921
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
Mixing Factor (Mf) = VWH Outlet Temp - Inlet Temp
70
First Hour Rating = Total VWH Output X VWH Eciency + .75 X Total Storage X Mf
[ (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 = 1.43
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 ] X 1.43
First Hour Rating = 628 X 1.43
First Hour Rating = 898 Gallons

WHL-053 Rev. 00 Rel. 003 Date 7.21.17
8
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 un-
even location surface. If surface ooring is rough, take care when
moving the boiler into position, as catching the leveling feet could
damage the boiler.
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
A. What’s in the Box
Remove all sides of the shipping crate of the boiler.
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.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17
9
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.
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.
A. Locating the Boiler
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.
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.
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.
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
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.
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.
Failure of the boiler or components due to incorrect operating
conditions IS NOT covered by product warranty.
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.
Do not mount the boiler to a hollow wall. Mount to the studs only.
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.
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
10
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.
CORRECT INCORRECT
Figure 1 - Correct and Incorrect Leveling
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.
B. Flooring
D. Clearances for Service Access
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.
Figure 2 - Recommended Service Clearances
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.
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.
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.
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.
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.
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.
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

WHL-053 Rev. 00 Rel. 003 Date 7.21.17
11
Failure to vent the boiler properly will result in serious personal
injury or death.
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.
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
2. Power Venting, Indoor Combustion Air in Conned or
Unconned Space
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.
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.
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.
G. Carbon Monoxide Detectors

WHL-053 Rev. 00 Rel. 003 Date 7.21.17
12
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
Failure to follow all instructions can result in ue gas spillage and
carbon monoxide emissions, causing severe personal injury or death.
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.
Figure 3 - CO Warning Label
Products to Avoid Areas Likely to Have
Contaminants
Spray cans containing
uorocarbons
Dry cleaning / laundry areas
and establishments
Permanent wave solutions Swimming pools
Chlorinated waxes / cleaners Metal fabrication plants
Chlorine-based swimming pool
chemicals Beauty shops
Calcium chloride used for thawing Refrigeration repair shops
Sodium chloride used for water
softening Photo processing plants
Refrigerant leaks Auto body shops
Paint or varnish removers Plastic manufacturing plants
Hydrochloric or Muriatic acid Furniture renishing areas
and establishments
Cements and glues New building construction
Antistatic fabric softeners used in
clothes dryers Remodeling areas
Chlorine-type bleaches, laundry
detergents, and cleaning solvents Garages and workshops
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.)
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
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.
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.
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.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17
13
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.
Contaminant
Maximum
Allowable
Level
Contami-
nant
Maximum
Allowable
Level
Total Hardness
(Commercial
Use - 140oF and
above water
temperature)
120 mg/l
(7 grains/gallon)
pH 6.5-8.5
Sulfate 205 mg/l
Total
Dissolved
Solids (TDS)
500 mg/l
Aluminum 0.05 to 0.2 mg/l Zinc 5 mg/l
Chloride 100 mg/l
Copper 1 mg/l Dissolved
Carbon
Dioxide (CO2)
15 mg/l or
PPM
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.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17
14
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
15
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
16
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.
A. General Plumbing Information
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.
The building piping system must meet or exceed the the piping
requirements in this manual.
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.
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.
B. Relief Valve
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.
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.
Connect discharge piping to a safe disposal location following the
guidelines below.
• 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.
• TestT&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.
RE-INSPECTION OF T&P RELIEF VALVES: T&P valves should be
inspected AT LEAST ONCE EVERYTHREE 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.
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.
FAILURE TO RE-INSPECT THE T&P VALVE AS DIRECTED COULD
RESULT IN UNSAFE TEMPERATURE AND/OR PRESSURE BUILD-
UP WHICH CAN RESULT IN PROPERTY DAMAGE, SERIOUS
PERSONAL INJURY, OR DEATH.
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
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.
The expansion tank must be suitable for hot potable water systems.
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.
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
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.
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.
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.
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.
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
18
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.
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
120oFMore than 5 minutes
125oF1 1/2 to 2 minutes
130oFAbout 30 seconds
135oFAbout 10 seconds
140oFLess than 5 seconds
145oFLess than 3 seconds
150oFAbout 1 1/2 seconds
155oFAbout 1 second
Table 7 - Approximate Time / Temperature Relationships in Scalds
H. High Velocity Circulator Pump
Minimum Boiler Flow Rates
VWH Model Minimum Flow (GPM)
220 14.6
299 / 301 20
399 26
Table 8 - Minimum Flow Rates
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.

WHL-053 Rev. 00 Rel. 003 Date 7.21.17
19
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 13’ 20
399 39’ 39 19’ 32.5 26
Table 10 - Temperature Rise, Friction Ft and Flow Rate
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
Figure 6 - Multiple Boiler Manifold Piping
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

WHL-053 Rev. 00 Rel. 003 Date 7.21.17
20
*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.
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.
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 non-
combustible 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.
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.
Contaminant
Maximum
Allowable
Level
Contami-
nant
Maximum
Allowable
Level
Total Hardness
(Commercial
Use - 140oF and
above water
temperature)
120 mg/l
(7 grains/gallon)
pH 6.5-8.5
Sulfate 205 mg/l
Total
Dissolved
Solids (TDS)
500 mg/l
Aluminum 0.05 to 0.2 mg/l Zinc 5 mg/l
Chloride 100 mg/l
Copper 1 mg/l Dissolved
Carbon
Dioxide (CO2)
15 mg/l or
PPM
Iron 0.3 mg/l
Manganese 0.05 mg/l