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Hamilton Engineering 299.2 Series Installing, Operating & Maintaining

High efficiency water heaters and heating boilers
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INSTALLING, OPERATING & MAINTAINING
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.
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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  • Page 1 INSTALLING, OPERATING & MAINTAINING 299.2/.3–599.2/.3 High Efficiency Water Heaters and Heating Boilers 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

    USING THIS MANUAL 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 judgment of the Manufacturer.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL ............. 2 PART 6. START-UP PROCEDURES ..... 48–56 A. Items to be Checked Before Lighting the Appliance ..48 TABLE OF CONTENTS ............3 B. Lighting Instructions ............48–49 C. Operating Instructions ............49 PART 1.

  • Page 4: Part 1. General Information

    PART 1. GENERAL INFORMATION PART 1. GENERAL INFORMATION A. HOW IT OPERATES BCB= The appliance product line is a high down as soon as the supply water the internal Boiler Control Board. efficiency water heating product, temperature has reached 50°F. Power and gas must be left on for requiring special venting and BDB =...
  • 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 TYPICAL APPLIANCE DISPLAY AS PART OF A CASCADE TYPICAL CASCADE DISPLAY TYPICAL STAND ALONE APPLIANCE DISPLAY Typical Cascade display—Heating and Indirect...
  • Page 6 PART 1. GENERAL INFORMATION As a Stand Alone Appliance HOT™ CONTROL MENU NAVIGATION...
  • Page 7 PART 1. GENERAL INFORMATION Appliance as Part of a Cascade HOT™ CONTROL MENU NAVIGATION...

  • Page 8: Appliance Control Panel

    PART 1. GENERAL INFORMATION B. APPLIANCE CONTROLS (FIGURE 1–1) The following components are found on the APPLIANCE CONTROL PANEL control panel on the front of the appliance. 1) POWER on/off switch 2) Display/Interface Standby Status Normal Operating Status in Cascade Press simultaneously while in SETUP area to activate Password Keyboard Normal Operating Status in single appliance...

  • Page 9: Appliance Control Board (Bcb) Screens

    PART 1. GENERAL INFORMATION C. APPLIANCE CONTROL BOARD (BCB) SCREENS Stand-By Mode: Operating Mode: In the main screen it is possible to see: • Set point value • Type of system (icons) • Date and time • Labels for navigation through the controller (STATUS, SET POINT, HISTORY, SETUP) •...
  • Page 10 PART 1. GENERAL INFORMATION C. APPLIANCE CONTROL BOARD (BCB) SCREENS (continued) HISTORY then to view ACTUAL FAULT: ACTUAL FAULT (HLO): In case of fault indication (SLO or HLO), the main page shows the code of the fault occurred. To see the extended description you have to go into HISTORY menu, where a new item “ACTUAL FAULT”...

  • Page 11: Cascade Display Functions

    PART 1. GENERAL INFORMATION D. CASCADE DISPLAY FUNCTIONS Standby Mode: Operating Mode (no demand): Icons here indicate what mode the appliance is in One or more appliances on: Flashing icon indicates demand in process (iDHW): Flame icon indicates that the appliance is in a burn cycle—shows proof of flame rectification One or more appliances HLO:...
  • Page 12 PART 1. GENERAL INFORMATION D. CASCADE DISPLAY FUNCTIONS (continued) Appliance A is the lead as indicated by the Both appliances are in a burn cycle. A is L. The A appliance is also in a burn cycle the lead and B is 2nd in line as indicated illustrated by the flame icon.
  • Page 13 PART 1. GENERAL INFORMATION (TABLE 1-1) SENSOR TABLES Number Sensor Part Name - Part Number Location - BCB - Boiler Control Board Supply temperature - Adjustable Manual Reset T1.1 BCB - appliance outlet pipe High Limit TST 75001 Supply temperature p/n see above, T1.2 BCB - appliance outlet pipe duplex sensor...

  • Page 14: Glossary

    PART 1. GENERAL INFORMATION E. GLOSSARY Air pressure switch Interface Cascade Manager (with or without WiFi) Indirect Tank Boiler Control Board Sanitary hot water tank with a built in heat exchanger often used as a component in an iDHW system Boiler Display Board Blocking Baseline data initialization, runs by default every 14 days...

  • Page 15: Dimensions

    PART 1. GENERAL INFORMATION F. DIMENSIONS Exhaust Exhaust Out (A) Out (A) Air In (A) Air In (A) Air Vent Air Vent (TABLE 1-1) APPLIANCE DIMENSIONS Model Width Heightt Depth 19" 33" 19" 4" 1.5" 1.5" 0.75" 19" 33" 19" 4"...

  • Page 16: Recommended Service Clearances

    PART 1. GENERAL INFORMATION 12" Clearance F. DIMENSIONS (continued) from top of unit RECOMMENDED SERVICE CLEARANCES (FIGURE 1-2) APPLIANCES CLEARANCES Zero Clearance from back of unit (NOTE: THE APPLIANCE IS RATED AT ZERO to wall CLEARANCE TO COMBUSTIBLES.) G. PRE-INSTALLATION REQUIREMENTS make sure all electric power to The appliance models 299–599 the appliance is turned off.

  • Page 17: Pressure Relief Valve

    PART 1. GENERAL INFORMATION (FIGURE 1-4 ) #1 TURN OFF POWER TO UNIT Turn off power at the breaker supplying power to the appliance. In a factory supplied Cascade package, turn off at the Intermediate Disconnect. Just turning off the on-off switch on the front of the appliance does not eliminate all power from within the appliance cabinet and electrical...

  • Page 18: Part 2. Electrical

    PART 2. ELECTRICAL PART 2. ELECTRICAL A. ELECTRICAL CONNECTION / REQUIREMENTS The electrical connection for the of equipment room electrical The electrical requirements are for appliance is on the bottom of the grounding issues, or equipment standard 208–240 volt split phase, unit.
  • Page 19 THE INFORMATION CONTAINED IN THIS 24 X 36 DRAWING IS THE SOLE PROPERTY OF FINISH DISAPPROVED, DO NOT FABRICATE HAMILTON ENGINEERING, INC. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF SCALE: 1:1 SHEET 1 OF 1 HAMILTON ENGINEERING<...
  • Page 20 PART 2. ELECTRICAL B. INTERNAL WIRING CONNECTION (continued) Yellow ADDITIONAL SAFETY CIRCUIT Rear Wall High temp Limit switch Yellow Optional Burner Door 14GA High temp Limit switch 14 GA Reset Button Reset Button for manual Reset Lwco conv. 14 GA Only - Not for Automatic LWCO Conv.
  • Page 21 COMMENTS THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF 24 X 36 FINISH HAMILTON ENGINEERING, INC. ANY DISAPPROVED, DO NOT FABRICATE REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF HAMILTON ENGINEERING< INC. IS...

  • Page 22: 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 23: 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 24 PART 3. GAS CONNECTION D. GAS VALVE SETUP (continued) Please see Part 6—Start-Up Procedures 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 25: Adjustment Table

    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 26: 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 27: Gas Conversion

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

  • Page 28: Part 4. Venting

    PART 4. VENTING PART 4. VENTING A. APPROVED VENTING MATERIALS ALL VENT PIPE MATERIALS AND FITTINGS MUST COMPLY WITH THE FOLLOWING: Standards for installation in: Item Material United States Canada AL 29-4C Stainless ANSI/ASTM UL1738 UL1738 PVC schedule 40* ANSI/ASTM D1785 CPVC and PVC venting must be ULC-S636 Vent pipe Certified.

  • Page 29: Venting The Appliance

    PART 4. VENTING B. VENTING THE APPLIANCE (TABLE 4-1) VENTING SPECIFICATIONS Vent Minimum Combined Vent Maximum Combined Model Diameter Standard Vent Type Optional Vent Type Length Length HW 299 4" Plastic Stainless 6' + (2) 90º elbows 225' HW 399 4"...

  • Page 30: Existing Common Vent Systems

    PART 4. VENTING B. VENTING THE APPLIANCE (continued) Exhaust piping should be sloped plus two 90° elbows. Choose your back to the connection on the vent termination locations carefully. appliance, at least 1/4” per foot (PP You must also make certain that piping above 5"...
  • Page 31 PART 4. VENTING Direct Vent Terminal Clearances...
  • Page 32 PART 4. VENTING Direct Vent Terminal Clearances (continued) Other Than Direct Vent Terminal Clearances...
  • Page 33 PART 4. VENTING Other Than Direct Vent Terminal Clearances (continued)
  • Page 34 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 appliance (to PLEASE NOTE: allow drainage of condensate).
  • Page 35 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 36 PART 4. VENTING B. VENTING THE APPLIANCE (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 37: Inlet Air Vent

    PART 4. VENTING C. INLET AIR VENT You may use the same material as used for exhaust or any material that is the same diameter that provides a pressure tight connection. THIS IS ONLY FOR INLET AIR, NOT FOR EXHAUST PIPING! The air inlet must be a minimum of 12"...

  • Page 38: Condensate Requirements

    PART 4. VENTING NOTE: Heat E. CONDENSATE REQUIREMENTS exchanger MUST be level or pitched slightly to the rear! This is a condensing high efficiency appliance, therefore this unit has a condensate removal system. Condensate is nothing more than water vapor derived from the combustion products, similar to an automobile when it is initially started.

  • Page 39: Part 5. Piping

    PART 5. PIPING PART 5. PIPING A. HYDRONIC HEATING BOILER PIPING The appliance is designed to function recommended, as shown in the of the highest heat transfer device, in a closed loop (minimum) 12 PSI Figure 5-1 below. Each appliance some state and local codes require a System.

  • Page 40: 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 41: Fill & Purge Heating System

    PART 5. PIPING C. FILL & PURGE HEATING (HYDRONIC) 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 42: Water Heating Piping

    PART 5. PIPING E. WATER HEATING PIPING 1 Use only the pipe sizes shown and a pump meeting the listed specifications in the following tables: *NOTE: Individual Appliance Piping pressure drop used in the tables is based on 20 feet of straight pipe, 6 elbows, 2 tees, 2 full port ball valves and 2 unions.

  • Page 43: 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 44 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 45 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 46 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 47 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 48: Part 6. Start-Up Procedures

    PART 6. START-UP PROCEDURES PART 6. START-UP PROCEDURES A. ITEMS TO BE CHECKED BEFORE LIGHTING THE APPLIANCE It is recommended that you read this 3. Make sure that the Gas is turned or other restriction is installed in entire section of Start-Up Procedures on outside the bottom of the the discharge line, and that the to get a better understanding of...

  • Page 49: Lighting Instructions

    PART 6. START-UP PROCEDURES B. LIGHTING INSTRUCTIONS (continued) 3. Turn on gas shutoff valve (located 4. Do not use this appliance if 5. The appliance shall be installed outside the cabinet on the bottom any part has been under water. so the gas ignition system of the appliance) so that the Immediately call a qualified service...
  • Page 50 PART 6. START-UP PROCEDURES D. INI PROCESS AND SERVICE PROCEDURES (continued) To force an INI to run (this can be done by appliance or individually): 1) Enter Setup menu 2) Press the back and down arrow simultaneously for 3 sec., to enter the password screen, and enter password level 1 (there is an advanced Level 2 with more options, available if you have attended training at the Manufacturer's factory).
  • Page 51 PART 6. START-UP PROCEDURES D. INI PROCESS AND SERVICE PROCEDURES (continued) Start Service Mode Procedure: 1) Enter Setup menu 2) Scroll down to service, and select using the √ button 3) Select burner, and then start 4) The display will return to the setup menu, and service mode has begun.

  • Page 52: Set Points

    PART 6. START-UP PROCEDURES E. ADJUSTING THE TEMPERATURE ON THE APPLIANCE DISPLAY On a single unit you change set point through the BDB, for multiple systems it is through the CDB. contact the Manufacturer. Other Enter the menu labeled Setpoint if there is none connected, it will in the upper right of the display operate based on the incoming...

  • Page 53: Adjusting The Temp On The Appliance Display

    PART 6. START-UP PROCEDURES WATER HEATER OPERATING SAMPLE All of the following parameters are controlled by a storage tank temperature sensor: • Setpoint = Target Temperature (120°F) Low fire only above this point • Offset = Off Setpoint (3) = 123°F off •...

  • Page 54: Sequence Of Operation

    PART 6. START-UP PROCEDURES F. 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 55 PART 6. START-UP PROCEDURES is set up with any other external signal here, this should be removed as well, or that external signal will take over when the 0-10VDC control signal drops below 1.0VDC. Next, go to Parameter S18 (PS18) in the Parameter menu and choose the appropriate control setting. (include picture of menu or HMI page) The PS18 settings are: •...

  • Page 56: Outdoor Reset Function

    PART 6. START-UP PROCEDURES H. OUTDOOR RESET FUNCTION Curve or slope—set using the display option in heating set point. (FIGURE 6–1) OUTDOOR RESET FUNCTION 1. You must have the Outdoor Sensor (10K) sensor installed, and the power must have been cycled on and off after its installation.

  • Page 57: Part 7. Service And Maintenance

    PART 7. SERVICE AND MAINTENANCE PART 7. SERVICE AND MAINTENANCE A. SERVICING THE APPLIANCE B. PLACING THE APPLIANCE INTO NORMAL OPERATION 1. Shut off the power supply to the 1. Replace the front cover in the appliance (See Part 1, Section D). normal position.

  • Page 58: Testing The Manual Reset High Limit

    PART 7. SERVICE AND MAINTENANCE C. TESTING THE MANUAL RESET HIGH LIMIT (continued) 3. The high limit test is only active for 10 minutes as a default, you can select a time less than that if desired, just push the down arrow until the appropriate time and then push √: •...

  • Page 59: Soft Lockout Codes

    PART 7. SERVICE AND MAINTENANCE D. SOFT LOCKOUT CODES (See Section 1, Part A for Sensor Locations and Uses)  (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...
  • Page 60 PART 7. SERVICING D. SOFT LOCKOUT CODES (continued)  (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 in Part 7, Section I, Inlet sensor (T2) fault (short circuit status) replace if out of range.

  • Page 61: Appliance Hard Lockout Codes

    PART 7. SERVICING E. APPLIANCE 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 62: 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 63: 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. APPLIANCE SENSOR RESISTANCE TABLE (TABLE 7-5) TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE (OHM) (OHM) 32550 32550 25340 25340 19870 19870...

  • Page 64: Part 8. Maintenance

    PART 8. MAINTENANCE PART 8. MAINTENANCE A. PERIODIC MAINTENANCE 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 65: 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 66 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 67 PART 8. MAINTENANCE • Check the fire side of the heat (See complete cleaning instructions exchanger: only clean loose in Part 8, Section D) residue from the heat exchanger • Check the distance from the coil, use a vacuum cleaner and electrode to the burner;...
  • Page 68 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 69 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 70: 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 6) Reinstall the clean-out cap on the appliance.

  • Page 71: 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 72 PART 8. MAINTENANCE D. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS* (continued) FIRE SIDE CLEANING 1) Shut down the appliance by using condensate hose is blocked, try the following steps: to knock any debris loose with a small screwdriver. Replace hose if a.
  • Page 73 PART 8. MAINTENANCE WATER SIDE CLEANING (de-scaling kit is required for this process, please consult factory) Detailed instructions on Water 1) Shut down the appliance and 2) Shut down the appliance and Side Cleaning can be found in clean by using the following clean by using the following steps for heaters: steps for boilers:...

  • Page 74: Heat Exchanger Anti-Scaling Prevention Feature

    PART 8. MAINTENANCE E. HEAT EXCHANGER ANTI-SCALING PREVENTION FEATURE The appliance 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 75: Part 9. Special Installation Reqs

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

  • Page 76: Installation At High Altitudes

    PART 9. SPECIAL INSTALLATION REQS B. INSTALLATION AT HIGH ALTITUDES • By adjusting the combustion This appliance is equipped with an To enter the operating elevation: characteristics as described automatic combustion characteristic • From the setup menu, enter the above, there is no de-rate adjustment system, provided the password for the installer level required at altitudes up to...

  • Page 77: Part 10. Parts Breakdown

    PART 10. PARTS BREAKDOWN PART 10. PARTS BREAKDOWN CASCADE BOX...
  • Page 78 PART 10. PARTS BREAKDOWN PARTS AND PRICING LIST FOR 299.2/.3–599.2/.3 LABEL DESCRIPTION PART# 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...
  • Page 79 PART 10. PARTS BREAKDOWN LABEL DESCRIPTION PART# 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 PANEL BTM 20GA CS 1010-1020 HW299-399 POWDER COAT D113884 CAP PROTECTION 0.48 ID PVC BLACK D108572 GROMMET SNAP IN 1/2 OD X 3/8 ID NYLON WHITE L...
  • Page 80 PART 10. PARTS BREAKDOWN PARTS AND PRICING LIST FOR 299.2/.3–599.2/.3 (continued) LABEL DESCRIPTION PART# ARM OUT EVO599 D104575 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...

  • Page 81: Part 11. Warranty Information

    PART 11. WARRANTY INFORMATION A. WARRANTY CONTACT INFORMATION Hamilton Engineering Company, Inc. warrants each appliance 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.

This manual is also suitable for:

299.3 series599.2 series599.3 seriesHwh 299.2Hwh 399.2Hwh 599.2 ... Show all

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