Hamilton Engineering EVO Plus Series Installing, Operating & Maintaining

Hamilton Engineering EVO Plus Series Installing, Operating & Maintaining

High efficiency water heaters and heating boilers
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INSTALLING, OPERATING & MAINTAINING
EVO 299.2/.3–599.2/.3 High Efficiency
Water Heaters and Heating Boilers
ANSI Z21.13-2014/CSA 4.9-2014
UL 795-2011/CSA 3.4
SCAQMD 1146.2
New York
Massachusetts
MEA 425-05-E
C1-0319-441
WARNING
If the information in this manual is not
followed exactly, a fire or explosion may
result causing property damage, personal
injury or death.
EVO 299.2/.3–599.2/.3
300,000 BTU/hr
399,000 BTU/hr
630,000 BTU/hr
Do not store or use gasoline or other flammable 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 instructions. If you cannot
reach your gas supplier, call the fire department.
SCAQMD
CEC Listed
Compliant Rule1146.2
California Energy Commission
WARNING
These appliances MUST be installed by a properly licensed individual in
the City and State which the unit is being installed. All start up adjustments
and subsequent service work must be done by a similarly licensed
contractor or a factory trained service individual. Failure to comply could
result in loss of warranty and or severe personal injury, death and or
substantial property damage. These instructions are required to be
kept with the appliance on the left side, in the pocket provided.

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Summary of Contents for Hamilton Engineering EVO Plus Series

  • Page 1 INSTALLING, OPERATING & MAINTAINING EVO 299.2/.3–599.2/.3 High Efficiency Water Heaters and Heating Boilers EVO 299.2/.3–599.2/.3 300,000 BTU/hr 399,000 BTU/hr 630,000 BTU/hr Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS: •...
  • Page 2: Using This Manual

    Throughout this manual you will see these special attention boxes similar to those below, which are intended to supplement the instructions and make special notice of potential hazards. These categories are in the judgement of Hamilton Engineering Company, Inc. DANGER...
  • Page 3: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL ............. 2 PART 6. START-UP PROCEDURES ......36 A. Items to Be Checked Before Lighting the EVO ..36 TABLE OF CONTENTS ............3 B. Lighting Instructions ............36–37 C. Operating Instructions ............37 PART 1.
  • Page 4: Part 1. General Information

    PART 1. GENERAL INFORMATION PART 1. GENERAL INFORMATION A. HOW IT OPERATES BCB= The EVO product line is an cycle will be initiated and will shut the internal Boiler Control Board. extremely high efficiency water down as soon as the supply water heating product, requiring special temperature has reached 50°F.
  • Page 5 PART 1. GENERAL INFORMATION BCB—Boiler Control Board BDB—Boiler Display Board CCB – Cascade Control Board CDB - Cascade Display Board EDB – Eeprom Data Board – contains all operating parameters of CCB and BCB...
  • Page 6: Glossary

    PART 1. GENERAL INFORMATION B. GLOSSARY Interface Cascade Manager (with or without WiFi) Air pressure switch Indirect Tank Sanitary hot water tank with a built in heat exchanger Boiler Control Board Baseline data initialization, runs by default every 14 days Boiler Display Board Blocking Lead-lag system...
  • Page 7: Dimensions

    PART 1. GENERAL INFORMATION C. DIMENSIONS Exhaust Exhaust Out (A) Out (A) Air In (A) Air In (A) Air Vent Air Vent Front View Left View Relief Valve Relief Valve Inlet (B) Outlet (C) Outlet (C) Gas (D) Condensate Trap Cleaning Point Condensate Trap Cleaning Point...
  • Page 8: Pre Installation Requirements

    Table 1-2 for weights). Be sure the installation. If the water quality Hamilton Engineering for correct appliance is adequately secured to exceeds any of the following levels, pump sizing. Combined, the the mounting surface.
  • Page 9: Pressure Relief Valve

    Before removing screw and opening front cover, main power supply must be disconnected (shut off). 240VAC Split Phase HIGH VOLTAGE - RISK OF ELECTRICAL SHOCK! INNOVATIVE CONDENSING TECHNOLOGY With HOT Controls by Hamilton Engineering Co., Inc. Customer Supplied Neutral 04-5 By Hamilton Engineering, Inc. White...
  • Page 10: Part 2. Electrical

    PART 2. ELECTRICAL PART 2. ELECTRICAL A. ELECTRICAL CONNECTION / REQUIREMENTS The electrical connection for the of equipment room (boiler or water The electrical requirements are for EVO is on the bottom of the unit. heater) electrical grounding issues, or standard 208–240 volt split phase, There is a 1/2”...
  • Page 11 PART 2. ELECTRICAL B. INTERNAL WIRING CONNECTION (continued) Black | White Ignition Transformer 03-11 Black 03-12 White Black White Optional White 3-Way Valve CN12 Black 03-13 Black 03-14 White Green Black 03-3 Black Black Green 03-3 Optional PWM Pump Black Brown Blue Blue...
  • Page 12: Part 3. Gas Connection

    PART 3. GAS CONNECTION PART 3. GAS CONNECTION A. GAS CONNECTION AND INSPECTION or utility in addition to the governing DANGER authority, prior to turning the gas Supply supply on. It is mandatory that a FAILURE TO FOLLOW ALL PRECAUTIONS drip leg be fabricated, as per the COULD RESULT IN FIRE, EXPLOSION OR DEATH!
  • Page 13: Gas Tables

    PART 3. GAS CONNECTION C. GAS TABLES (TABLE 3-1) NATURAL GAS SUPPLY PIPING Nominal Internal Length in Pipe (feet) Iron Pipe Diameter Size (in) Inches 0.824 72 } BTUs 1.049 135 } per HR 1-1/4 1.380 1,404 278 } x 1,000 1-1/2 1.610 2,103...
  • Page 14 PART 3. GAS CONNECTION D. GAS VALVE SETUP (continued) Please see Part 6—Start-Up Procedures on page 36 before continuing! Proper gas volume and pressure is • Maximum load—all appliances • Gas pressure for maximum critical to the operation of any high on at full fire that are being load shall be measured with all efficiency appliance.
  • Page 15: Setting The Maximum Load

    PART 3. GAS CONNECTION (TABLE 3-3) COMBUSTION & FUEL RELATED ADJUSTMENT TABLE Natural Gas CO Natural Gas CO ppm LP Gas CO LP Gas CO ppm Cover On Cover Off Approximate, do not use for setup! Cover On Cover Off Approximate, do not use for setup! LOW FIRE 8.5%...
  • Page 16: Setting The Minimum Load

    PART 3. GAS CONNECTION (TABLE 3-5) FAN SPEED REQUIREMENTS HW 299 Fan Type Maximum RPM Minimum RPM 6300 1575 Ametek 6500 1625 HW 399 Fan Type Maximum RPM Minimum RPM 6200 1798 Ametek 7200 1800 HW 599 Fan Type Maximum RPM Minimum RPM 5800 1624...
  • Page 17: Gas Conversion

    PART 3. GAS CONNECTION G. GAS CONVERSION If the appliance is to be converted in valve closed (clockwise) and • After conversion, follow the steps the field for using Propane (LPG), the turn right valve 1-¾ of a full turn in Sections E and F for setting the following steps must be taken: clockwise.
  • Page 18: Part 4. Venting

    EVO must be CPVC Schedule 40 or 80 or stainless. The balance from the penetrated wall to the outside may be PVC Schedule 40 or 80. NOTE: If set points exceed 140ºF, use of PVC is NOT recommended, even though product is approved as such. Contact Hamilton Engineering at 800.968.5530 for further clarification.
  • Page 19: Venting The Evo

    Stainless Plastic - 6"* 6' + (2) 90º elbows 200' *The use of 6" PVC will require the purchase of a special adapter from Hamilton Engineering Company, Inc. (TABLE 4-2) EQUIVALENT FEET Fittings or Piping Equivalent Feet 90 degree elbow...
  • Page 20 Several methods for venting the EVO can be found in Figures 4-2 through 4-6 of this section. Use these layouts as guidelines: certain site conditions such as multiple roof lines/ pitches may require venting modifications (consult Hamilton Engineering Company, Inc.).
  • Page 21 PART 4. VENTING *IMPORTANT NOTE HAMILTON ENGINEERING COMPANY, INC. RECOMMENDS A MINIMUM CLEARANCE OF 4 FEET WHERE THE EXHAUST PLUME CAUSED BY THE UNIT MAY OBSTRUCT VIEWS OR AFFECT THE COSMETIC LOOK OF THE BUILDING. IN CANADA, THERE IS A MINIMUM CLEARANCE OF 10 FEET.
  • Page 22 Fitting Before Vertical Run **IMPORTANT NOTE: All vent pipes must be glued, With HOT Controls by Hamilton Engineering Co., Inc. properly supported and the exhaust must be pitched a minimum of a 1/4" per foot back to the heater (to allow PLEASE NOTE: drainage of condensate).
  • Page 23 All horizontal runs must be every 24” (CPVC only) supported every 24" Recommended Drain Recommended Drain Fitting Before With HOT Controls by Hamilton Engineering Co., Inc. Fitting Before Vertical Run Vertical Run (CPVC only) Customer / Job name: Description: Reference dimensions are ± 10%...
  • Page 24 PART 4. VENTING B. VENTING THE EVO (continued) CAUTION DIAGRAMS FOR ROOM AIR VENTING TERMINATION Flue Gas will condense as it exits the vent If you’re using room air, your unit should be set up this way: termination. This condensate can freeze on exterior building surfaces which may cause discoloration of these surfaces.
  • Page 25: Inlet Air Vent

    If the combined venting length of a heater’s exhaust/inlet air system exceeds the Maximum Combined Length called out in Table 4-1, Page 23, contact Hamilton Engineering, Inc. for an engineered venting calculation. Do not proceed without calling Hamilton Engineering Co, Inc. at 800.968.5530.
  • Page 26: Condensate Requirements

    To disable operation, turn off gas, event of a condensate drain blockage. Please test annually. NOT power. If you have any questions, please call Hamilton Engineering Technical Maximum volume of condensate produced is 11 gallons per hour per Support at 800.968.5530.
  • Page 27: Part 5. Piping

    Basic piping connection steps are listed below. A drawing, specific to your application can be obtained from your distributor or Hamilton Engineering, Inc., which will guide you through proper installation of the EVO. 1) Pipe properly, in accordance with generally accepted piping principals or Hamilton Engineering specific documents.
  • Page 28: Boiler Schematic Drawings

    Hot Water Return Pump Cold Water Ball valve Condensate Drain Fill Valve PART 5. PIPING EVO Boiler Stand Mounted Flow direction Expansion Tank Pressure Relief valve Condensate Neutralizer Gas cock Floor Drain Hamilton System Separator B. BOILER SCHEMATIC DRAWINGS Drain valve Temperature Sensor Air vent Boiler pump...
  • Page 29: Fill & Purge Heating System

    PART 5. PIPING C. FILL & PURGE HEATING SYSTEM be damaged by build-up or 1) Attach hose to balance and purge Upon completion, make sure that the corrosion due to sediment. hose connector and run to drain. fill valve is in automatic position and each zone balance and purge valve •...
  • Page 30: Water Heating Piping

    Upon completion of piping, fill and properly purge of all air. Open all valves and start circulating pump. Consult Hamilton Engineering for specific piping diagrams for your application at 800.968.5530. NOTE: Minimum pump selection is based on piping sizes shown above and water hardness not to exceed 15 grains per gallon and total maximum equivalent piping length of 60 feet.
  • Page 31: Water Heating Schematic Drawings

    PART 5. PIPING LEGEND LEGEND F. WATER HEATING SCHEMATIC DRAWINGS Hot Water Supply Thermometer Hot Water Return Pump From System Cold Water Ball valve To System Condensate Drain Check valve One water heater Water Heater with Stand Aquastat schematic to single tank Storage Tank Flow direction Expansion Tank...
  • Page 32 PART 5. PIPING F. WATER HEATING SCHEMATIC DRAWINGS (continued) From System To System LEGEND One water heater schematic to single tank with mixing Hot Water Supply valve and CWIS Hot Water Return ™ Cold Water Tempered Water Supply Tempered Water Return Condensate Drain Water Heater with Stand Make-up...
  • Page 33 PART 5. PIPING From System To System LEGEND Three water heater Hot Water Supply schematic to single tank Hot Water Return Cold Water Condensate Drain Water Heater with Stand Make-up Storage Tank Water Expansion Tank Condensate Neutralizer Thermometer Pump Ball valve Check valve WH-1 WH-2...
  • Page 34 PART 5. PIPING F. WATER HEATING SCHEMATIC DRAWINGS (continued) LEGEND Three water heater schematic Hot Water Supply Ball valve to single tank with mixing Hot Water Return Check valve valve AND CWIS ™ Cold Water Aquastat From System To System Tempered Water Supply Flow direction Tempered Water Return...
  • Page 35 PART 5. PIPING LEGEND Hot Water Supply Thermometer To System Hot Water Return Pump Cold Water Ball valve From System Condensate Drain Check valve Three water heater Water Heater with Stand Aquastat schematic to two tanks Storage Tank Flow direction Expansion Tank Pressure Relief valve Condensate Neutralizer...
  • Page 36: Part 6. Start-Up Procedures

    PART 6. START-UP PROCEDURES PART 6. START-UP PROCEDURES A. ITEMS TO BE CHECKED BEFORE LIGHTING THE EVO It is recommended that you read 3. Make sure that the Gas is turned or other restriction is installed in the General Information Section on outside the bottom of the the discharge line, and that the (Part 1, Page 4-13) to get a better...
  • Page 37: Lighting Instructions

    On a water heater it menu, then display options. temperature settings are required, will be based either on a connected contact Hamilton Engineering external (storage tank) sensor, or, Company, Inc. Other special if there is none connected, it will...
  • Page 38: Sequence Of Operation

    PART 6. START-UP PROCEDURES E. SEQUENCE OF OPERATION DANGER WATER TEMPERATURE OVER 125ºF CAN CAUSE SEVERE BURNS INSTANTLY, OR DEATH FROM SCALDS. CHILDREN, THE DISABLED, AND THE ELDERLY ARE AT HIGHEST RISK OF BEING SCALDED. SEE INSTRUCTION MANUAL BEFORE SETTING TEMPERATURE AT WATER HEATER.
  • Page 39: C Evo Soft Lockout Codes

    PART 7. SERVICING C. EVO SOFT LOCKOUT CODES (TABLE 7-1) CCB SOFT LOCK OUT (SLO) CODES Code Cause Recommended Action CCB01 Sensor S1 fault Check that the S1 sensor is connected CCB02 Sensor S2 fault Check that the S2 sensor is connected CCB03 Sensor S3 fault Check that the S3 sensor is connected...
  • Page 40 PART 7. SERVICING (TABLE 7-2) BCB SOFT LOCK OUT (SLO) CODES (continued) Code Cause Recommended Action Take an OHM reading on the inlet sensor - compare it to the chart on page 47 replace if out of Inlet sensor (T2) fault (short circuit status) range.
  • Page 41: Evo Hard Lockout Codes

    PART 7. SERVICING D. EVO HARD LOCKOUT CODES (TABLE 7-3) BCB HARD LOCKOUT (HLO) CODES Code Cause Recommended Action A1/A2 Excessive pressure differential (∆P) on water side of heat exchanger Check for scaling or blockage on water side of heat exchanger, also check pump performance. Neutralizer/trap has little or no Condensate (water) Fill neutralizer (or trap if not a factory neutralizer) with water to avoid flue gases spilling into the room through a dry trap.
  • Page 42: To Turn Off Gas To The Appliance

    PART 7. SERVICING (TABLE 7-3) BCB HARD LOCKOUT (HLO) CODES (continued) Code Cause Recommended Action Water flow too low through appliance Check for partially closed valves, pump impeller fouling etc. Water flow blocked during a burn cycle (proof of flow) Check for partially closed valves, pump impeller fouling etc.
  • Page 43: Status Readings

    PART 7. SERVICING H. STATUS READINGS (FIGURE 7-4) STATUS READING INSTRUCTIONS Sensor list and other details on screens will vary from system to system I. EVO SENSOR RESISTANCE TABLE (TABLE 7-5) EVO SENSOR RESISTANCE TABLE TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE (OHM) (OHM) 32550 32550...
  • Page 44: Part 8. Maintenance

    PART 8. MAINTENANCE PART 8. MAINTENANCE A. PERIODIC MAINTENANCE OF HEATER AND INSPECTIONS All high efficiency condensing that all the equipment is in safe, required, shall become the required efficient operation. Failure to do so appliances will require more regular future minimum cleaning interval, may eliminate warranty coverage.
  • Page 45: Annual Inspection

    PART 8. MAINTENANCE B. ANNUAL INSPECTION (See LIT91179 Maintenance Checklist for required tools and materials) An inspection should cover, at a minimum, the following areas: • Inspect all fittings, controls and connections for leaks, damage, or fouling • Fire side: Heat exchanger Burner and ignitor Burner door and rear wall insulation...
  • Page 46 PART 8. MAINTENANCE B. ANNUAL INSPECTION (continued) Complete burner, door & fan assembly removed for inspection NOTE: Over-tightening the M6 • Dismantle the burner unit: remove it or if there is nuts may cause the threaded the (6) 6mm nuts (with a 10mm any physical rods on the front of the heat socket), the ignition cable, the...
  • Page 47 PART 8. MAINTENANCE • Check the fire side of the heat (See complete cleaning instructions exchanger: only clean loose on page 50–52) residue from the heat exchanger • Check the distance from the coil, use a vacuum cleaner and electrode to the burner; there nylon brush, and do not push the should be a 3/8"...
  • Page 48 PART 8. MAINTENANCE B. ANNUAL INSPECTION (continued) TESTING The following steps require the power supply be turned back on; extreme caution must be exercised when performing service with the power supply on and the door off. • When turning the appliance back on, listen for significant noises from the fan and pump. Also, inspect for leaks at the pump connections.
  • Page 49 PART 8. MAINTENANCE Try to keep the measuring hose flat with the inner wall of the pipe. Use a small opening to insure you are measuring static pressure and not velocity pressure P (1, 2, 3) A These will be negative pressures relative to atmosphere P (1, 2, 3) F These will be positive pressures relative to atmosphere Example...
  • Page 50: Condensate Trap Cleaning Instructions

    PART 8. MAINTENANCE C. CONDENSATE TRAP CLEANING INSTRUCTIONS NOTE: The condensate trap and entire drain system attached to it (above the neutralizer) should be cleaned at least once every year. 1) Turn off the power to the EVO. 6) Reinstall the clean-out cap on the condensate trap.
  • Page 51: Combustion Chamber Coil Cleaning Instructions

    PART 8. MAINTENANCE D. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS* *Before beginning this procedure, you must have the following items on hand: • Nylon brush—DO NOT use brass, stainless or steel brushes. • Water • Vacuum cleaner • Fernox F3 Cleaner •...
  • Page 52 PART 8. MAINTENANCE D. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS* (continued) WATER SIDE CLEANING (de-scaling kit is required for this process, please consult factory) Detailed instructions on Water 1) Shut down the EVO and clean by 2) Shut down the EVO and clean by Side Cleaning can be found in using the following using the following...
  • Page 53: Evo Controls

    PART 8. MAINTENANCE E. EVO CONTROLS DANGER IT IS EXTREMELY IMPORTANT THAT YOU CHECK FOR LEAKS WHEN RECONNECTING THE GAS VALVE AND MAKE SURE THE EXHAUST VENT IS NO LONGER BLOCKED. FAILURE TO DO SO MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH. The following components are found on the control panel on the front of the appliance.
  • Page 54: Coil Anti-Scaling Prevention Feature

    PART 8. MAINTENANCE F. COIL ANTI-SCALING PREVENTION FEATURE The EVO controller contains used. If the Anti-Scale setting is Typical causes for repeated H11 sophisticated software that reached, the unit will display H11, indications at start up are air enables it to monitor the rate of shut down and not re-fire until it trapped in the heat exchanger temperature rise through the heat...
  • Page 55: Part 9. Special Installation Reqs

    PART 9. SPECIAL INSTALLATION REQS PART 9. SPECIAL INSTALLATION REQS A. INSTALLATION REQUIREMENTS—MASSACHUSETTS Requirements for installation—Commonwealth of Massachusetts a. In the event that the side wall heating appliance or equipment. For all side wall horizontally vented gas fueled equipment installed horizontally vented gas fueled The sign shall read, in print size in every dwelling, building or...
  • Page 56: Installation At High Altitudes

    PART 9. SPECIAL INSTALLATION REQS B. INSTALLATION AT HIGH ALTITUDES This appliance is equipped with an • The adjusted altitude entered is automatic combustion characteristic internally converted to an offset adjustment system, provided the on top of the maximum fan speed. installed elevation above sea level •...
  • Page 57: Part 10. Parts Breakdown

    PART 10. PARTS BREAKDOWN PART 10. PARTS BREAKDOWN...
  • Page 58 PART 10. PARTS BREAKDOWN ITEM # PART DESCRIPTION PART NUMBER PANEL FRONT DOOR EVO299-399HOT ASSY W/BEVEL WIN D116957 DOOR ASSY EVO599HOT FLAT WINDOW D109348 BURNER INL HW599 AIR/GAS D105610 PILOT SPARK ELECTRODE ASSEMBLY 79-599 KNURLED PLT 94318 A GASKET 3-5/16 OD EPDM 60 DURO TUBE/BURNER D104184 BURNER DOOR HW79-599 D105611...
  • Page 59 PART 10. PARTS BREAKDOWN ITEM # PART DESCRIPTION PART NUMBER PANEL SHEET METAL BOTTOM ASSEMBLY 299-399 JKB 94102 B PANEL BTM 18GA CS A1008 TB HW599HOT PWDR COAT D108482 PANEL BTM ASSY HW599HOT D109370 CAP PROTECTION 0.48 ID PVC BLACK D108572 GROMMET SNAP IN 1/2 OD X 3/8 ID NYLON WHITE L D108574...
  • Page 60 PART 10. PARTS BREAKDOWN ITEM # PART DESCRIPTION PART NUMBER ARM INLET HW599 HC D104574 GASKET 3/4 OD EPDM 70A DURO SQ HOLES FAST CONNECT ARM 399/599 D104191 PLUG PIPE 1/2 NPT BRS SQ HD SCH40 LF D30035 NIPPLE TBE 3/4 NPT X 3 BRS SCH40 D10861 ELBOW 90 3/4 NPT CU UNS C87850 LF D11029...
  • Page 61: Appendix. Addl Electrical Drawings

    APPENDIX. ADDITIONAL ELECTRICAL DRAWINGS APPENDIX. ADDITIONAL ELECTRICAL DRAWINGS MAIN POWER & RELAY ASSEMBLY AND CASCADE WIRING FOR EVO...
  • Page 62: Main Power & Relay Assembly

    APPENDIX. ADDITIONAL ELECTRICAL DRAWINGS MAIN POWER & RELAY ASSEMBLY POWER TO PUMP MAIN POWER GAS VALVE RELAY PUMP RELAY...
  • Page 63: Cascade Box With 3G Router

    APPENDIX. ADDITIONAL ELECTRICAL DRAWINGS CASCADE BOX WITH 3G ROUTER...
  • Page 64: Part 11. Warranty Information

    PART 11. WARRANTY INFORMATION A. WARRANTY CONTACT INFORMATION Hamilton Engineering Company, Inc. warrants each EVO Water Heater and Boiler to be free from defects in material and workmanship according to terms, conditions and time periods. Unless otherwise noted, these warranties commence on the date of installation.

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