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• Check the fire side of the heat

exchanger: only clean loose

residue from the heat exchanger

coil, use a vacuum cleaner and

nylon brush, and do not push the

residue between the openings

of the coils if at all possible as

this may impede the flow of the

products of combustion.

• Use inspection mirror to check

all heat passage spaces between

coils, and using a short, thin

putty knife or strip of stainless

steel, remove all debris.

These

passages MUST be free and

clear for proper heat transfer

to occur.

Rinse well all loose

debris that was pushed down to

the bottom of the condensate

collection tray.

• It is recommended to only use

clear water to rinse any remaining

residue away—the water

will automatically flow to the

condensate drain point.

•

If surface or coil gap fouling

still exists after the above

measures have been taken,

the heat exchanger requires

additional cleaning.

Use a non-

acid based cleaning solution, such

as Fernox F3, to thoroughly soak

the remaining residue. Brush

clean and then completely rinse

all residue and cleaning solution

down the condensate drain

assembly. Repeat if necessary.

(See complete cleaning instructions

on page 50–52)

• Check the distance from the

electrode to the burner; there

should be a 3/8" gap in between

the two. If the existing electrode

pins must be adjusted for proper

gap, caution must be exercised,

as they will likely be brittle from

exposure to the flame; try to

bend them as close to the burner

door insulation as possible using

two pair of pliers; one to support

the rod, and one to bend with.

New electrodes will be less

susceptible to breakage during

adjustment. The metal surface

of the electrodes should also

be carefully cleaned with

emery cloth.

NOTE: Do not make any

adjustments or cleaning with

the electrode still mounted to

the burner door, as damage to

refractory may result!

• Dismantle the air gas mixing

plate or chamber on the

suction side of the fan

and check for fouling. If

required, clean the fan

blade wheel and the air

gas mixing box.

• Reassemble the burner chamber,

making sure there is no

moisture on any of the

fireside components.

PART 8. MAINTENANCE

Cleaned heat exchanger—

prior to rear wall installation

Cleaned heat exchanger—

after rear wall installation

Burner & door assembly—

prior to fiberboard installation

Содержание EVO Plus Series

Страница 1: ...is manual is not followed exactly a fire or explosion may result causing property damage personal injury or death WARNING New York Massachusetts SCAQMD CEC Listed MEA 425 05 E C1 0319 441 Compliant Ru...

Страница 2: ...L MODELS A FACTORY ENGINEERED VENTING SYSTEM MAY ALLOW FOR EXCEPTIONS CONSULT FACTORY FOR DETAILS THIS HEATER INSTALLATION MUST CONFORM TO THE LATEST EDITION OF THE NATIONAL FUEL GAS CODE ANSI Z223 1...

Страница 3: ...Water Heating Schematic Drawings 31 35 PART 6 START UP PROCEDURES 36 A Items to Be Checked Before Lighting the EVO 36 B Lighting Instructions 36 37 C Operating Instructions 37 D Adjusting the Tempera...

Страница 4: ...ture drops to 37 F a burn cycle will be initiated and will shut down as soon as the supply water temperature has reached 50 F Power and gas must be left on for this function to operate The appliance s...

Страница 5: ...PART 1 GENERAL INFORMATION BDB Boiler Display Board CDB Cascade Display Board BCB Boiler Control Board CCB Cascade Control Board EDB Eeprom Data Board contains all operating parameters of CCB and BCB...

Страница 6: ...ce Hysterese Blocking set temperature offset temperature hysterese is starting temperature for the boiler ICM Interface Cascade Manager with or without WiFi Indirect Tank Sanitary hot water tank with...

Страница 7: ...379 999 466 582 776 26 4 20 3 17 6 8 5 204 lbs HW 599 630 000 up to 611 100 up to 598 500 734 917 1223 39 6 23 6 26 4 9 4 260 lbs 3 4 1 Reference dimensions are 10 All dimensions are 1 Custom Dwg No C...

Страница 8: ...e cover see Figure 1 4 on the next page If the EVO is set up for liquefied petroleum LP gas some geographic areas follow the Uniform Mechanical Code section 304 6 Liquefied petroleum gas burning appli...

Страница 9: ...ircumstances shall Hamilton Engineering Inc be held liable for any such water damage whatsoever E PRESSURE RELIEF VALVE FIGURE 1 4 HOW TO REMOVE THE FRONT COVER 1 TURN OFF POWER TO UNIT X1 1 2 3 4 120...

Страница 10: ...rought in to correct the problem The electrical requirements are for standard 208 240 volt split phase 50 60 Hz 15 Amp service When the unit is first powered on there is a self setting of the electron...

Страница 11: ...22 Red Black 22 Red Black 22 Yellow Black 22 Yellow Black 22 Violet 22 Violet 18 Yellow 18 Yellow 18 Yellow 18 Yellow 18 Black 18 Blue White 18 Blue White 22 Grey 22 Grey 22 Orange 22 Orange 22 Green...

Страница 12: ...ting instructions in Part 6 Section B Page 38 This will prevent high pressure from reaching the valve Failure to do so may damage the gas valve In the event the gas valve is exposed to a pressure grea...

Страница 13: ...150 200 BTUs per HR x 1 000 3 4 0 824 363 249 200 171 152 138 127 118 111 104 93 84 72 1 1 049 684 470 377 323 286 259 239 222 208 197 174 158 135 1 1 4 1 380 1 404 965 775 663 588 532 490 456 428 40...

Страница 14: ...Minimum load at ignition of a single unit in a multiple unit rack Maximum load all appliances on at full fire that are being tested and any other gas fired equipment on the same gas supply How and wh...

Страница 15: ...ns greater than 80 F please use the following table in adjusting your CO2 for optimum performance TABLE 3 3 COMBUSTION FUEL RELATED ADJUSTMENT TABLE Inlet air T variation Setup at minimum incoming air...

Страница 16: ...2 for the minimum setting first remove the protective cap Turn the screw clockwise to increase or counter clockwise to decrease the CO2 percentage On the HW 599 you only are allowed to set the gas val...

Страница 17: ...et up to factory specifications before any combustion related adjustments can be performed on the right hand valve An electronic manometer must be used as it will be set to a scale of 0 01 WC The adju...

Страница 18: ...ENCY TESTING AND RATINGS ARE BASED ON A SEALED TWO PIPE VENT SYSTEM HOWEVER MANY OTHER VENT CONFIGURATIONS ARE AVAILABLE AS FACTORY ENGINEERED SOLUTIONS PLEASE CONTACT THE FACTORY IF EXCEPTIONS ARE RE...

Страница 19: ...the cabinet should be the diameter and material indicated in the Venting Specifications Table above It is very important that you plan the location properly to eliminate long pipe runs and excessive...

Страница 20: ...ake and exhaust must be properly cleaned and glued if plastic and sealed per the manufacturer s directions if stainless for a pressure tight joint Several methods for venting the EVO can be found in F...

Страница 21: ...pliances 2 A through the wall mechanical draft venting system of other than direct vent type shall terminate at least 4 ft 1 2 m below 4 ft 1 2 m horizontally from or 1 ft 300 mm above any door operab...

Страница 22: ...t Elevation 8 18 Minimum 24 Maximum Front Elevation Multiple Vents 8 18 Minimum 24 Maximum OR min min 22 PART 4 VENTING B VENTING THE EVO continued PLEASE NOTE Exhaust must not terminate beneath an ov...

Страница 23: ...2 above Maximum snow level whichever is greater 18 Minimum 24 Maximum 8 Minimum Install Flanged Break Point To Check Non Return Damper During Anual Maintenance Min 12 Above Parapet wall if within 10 o...

Страница 24: ...set up this way NOTE Stated efficiencies are based on ducted air using room air may effect efficiency FIGURE 4 5 VERTICAL TERMINATION FIGURE 4 6 SIDEWALL TERMINATION As long as the boiler room remains...

Страница 25: ...oth inlet and exhaust piping for the EVO HW 299 maximum combined equivalent length is 225 feet Required 6 Pcs 90 elbow 6 x 5 30 equivalent feet 30 equivalent feet Required 20 of Plastic PVC Pipe 20 x...

Страница 26: ...cy 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...

Страница 27: ...ove are for clean closed loop systems PART 5 PIPING A HYDRONIC HEATING BOILER PIPING The EVO is designed to function in a closed loop minimum 12 PSI System Never let the EVO operate without a minimum...

Страница 28: ...cked Apv by Revision AE 12 13 10 Schematic Piping Diagram PID 3 HWH to HSS IHET B 1 CNK B 3 B 2 CD CD CD CD BP 1 BP 2 BP 3 CW HWR HWS HWR IHET ET From System Make up Water TS ZH ZP 1 HSS TS Supply to...

Страница 29: ...e strainer may be necessary For boiler water and or odd water systems please make note of these additional guidelines Thoroughly flush the system without boiler connected to remove sediment The high e...

Страница 30: ...iency can be obtained through use of our optional CWIS Cold Water Injection System in any Hamilton Storage Tank 3 Isolation valves should be installed on each heater and on the cold and hot water syst...

Страница 31: ...tomer Job name Scale Description Date Drawn Revised by Checked Apv by Revision Description Date Drawn Revised by Checked Apv by Revision AE 09 17 10 Schematic Piping Diagram PID 1 HWD to 1 HET TMV CW...

Страница 32: ...12 17 10 1 Reference dimensions are 10 All dimensions are 1 MM DD YY MM DD YY 1 2 1 Custom Dwg No Customer Job name Scale Description Date Drawn Revised by Checked Apv by Revision Description Date Dra...

Страница 33: ...Water TS From Tank To Tank Reference dimensions are 10 All dimensions are 1 MM DD YY MM DD YY 1 2 1 Custom Dwg No Customer Job name Scale Description Date Drawn Revised by Checked Apv by Revision Des...

Страница 34: ...erence dimensions are 10 All dimensions are 1 MM DD YY MM DD YY 1 2 1 Custom Dwg No Customer Job name Scale Description Date Drawn Revised by Checked Apv by Revision Description Date Drawn Revised by...

Страница 35: ...0 All dimensions are 1 MM DD YY MM DD YY 1 2 1 Custom Dwg No Customer Job name Scale Description Date Drawn Revised by Checked Apv by Revision Description Date Drawn Revised by Checked Apv by Revision...

Страница 36: ...curs Ensure that no reducing coupling or other restriction is installed in the discharge line and that the discharge line is installed to allow complete drainage of both the valve and the line 7 Turn...

Страница 37: ...e to off The handle will be horizontal do not force it 5 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow the instructions from Section B Lighting Instructions in the safety...

Страница 38: ...state the blower will be on at 80 At any time if an external thermostat is being used and becomes satisfied the gas valve will be closed immediately 6 When the post purge is complete the control ente...

Страница 39: ...f obstructions Also be sure the Z INI has been initiated B03 Pressure too low at condensate drain connection during pre purge Check for condensate water in the condensate neutralizer if equipped or th...

Страница 40: ...6 fault short circuit status Take an OHM reading on the wires from the external sensor in the piping or low lass header compare it to the chart on page 47 replace if out of range ID19 A Tank sensor T3...

Страница 41: ...d data on microcontroller Flash memory Reset the fault cycle power on and off if the fault reappears the EMB EEPROM is corrupted ID04 Internal fault gv1 Reset the fault cycle power on and off if the f...

Страница 42: ...OFF GAS TO THE APPLIANCE 1 Set the thermostat to lowest setting 2 Turn off power switch on front of unit 3 Turn off all electric power to the appliance if service is to be performed 4 Turn gas shutof...

Страница 43: ...0 50 19870 10 19870 59 15700 15 15700 68 12490 20 12490 77 10000 25 10000 86 8059 30 8059 95 6535 35 6535 104 5330 40 5330 113 4372 45 4372 122 3605 50 3605 131 2989 55 2989 140 2490 60 2490 149 2084...

Страница 44: ...hat inspections of all connection points and the combustion chamber be done at three month intervals any signs of fouling or leaks must be thoroughly investigated immediately as failure to do so may v...

Страница 45: ...ate neutralizer Test all safeties and operating controls Water side temperature rise T test INSPECTION AND CLEANING photos illustrating each step follow sets of instructions CAUTION Before removing th...

Страница 46: ...causethethreaded rodsonthefrontoftheheat exchangertobreak Ifexcess resistanceisencounteredwhen installingaM6nut discardthat nutanduseoneofthespares shippedwiththeunit The maximumtorqueforassembling ab...

Страница 47: ...solution down the condensate drain assembly Repeat if necessary See complete cleaning instructions on page 50 52 Check the distance from the electrode to the burner there should be a 3 8 gap in betwe...

Страница 48: ...an unusual number of G01 faults or if combustion is off significantly gas supply pressure must be verified at static no load and full building load conditions See Table 3 3 Page 15 for specific setti...

Страница 49: ...e gasses All readings must be taken with boiler front cover installed Doing the measurements under these conditions will give the most accurate results There may be minor differences between appliance...

Страница 50: ...y dirt or buildup that may have accumulated 5 Condensate drain assembly should now be checked for non restricted flow throughout the entire assembly 6 Reinstall the clean out cap on the condensate tra...

Страница 51: ...damage spray the coils liberally making sure the water penetrates and funnels down through the condensate hose If the condensate hose is blocked try to knock any debris loose with a small screwdriver...

Страница 52: ...flow to flush out any build up that may have occurred in the coils d Flush the system of all the Fernox DS 40 e After the system has been flushed add the Fernox F1 Inhibitor Protector for closed loop...

Страница 53: ...switch 2 Display Interface 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...

Страница 54: ...splay H11 shut down and not re fire until it has cooled The first 3 times this happens there will be a reduction of the maximum firing rate The fault will be accompanied by either an A B or C suffix i...

Страница 55: ...n can not 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...

Страница 56: ...installer level or higher Enter the parameters menu then the altitude parameter set Enter the appropriate elevation for the installation The adjusted altitude entered is internally converted to an off...

Страница 57: ...57 PART 10 PARTS BREAKDOWN PART 10 PARTS BREAKDOWN...

Страница 58: ...F PRESS M20 CONN CNDS HW79 599 NOT SHOWN D113636 17 BRACKET PROTECTION HW299 599 CS TB G30 BOILER CTRL D107939 18 DISPLAY BOILER BRD D107557 19 SWITCH RKR ON OFF 20A 250V DPST D108302 20 PANEL DWR HW2...

Страница 59: ...D104923 45 GROMMET 1 875 OD SILICONE AIR VENT TUBE BLACK D104189 46 ROD TBE 0 54 X 9 73 SS MT304 HW299 599 AIR VENT D108337 47 VENT AIR 1 8 NPT AUTOMATIC BRS D104903 48 PANEL REAR EVO299 399HOT D1145...

Страница 60: ...W599 GAS D104275 74 MANIFOLD GAS INL HW599 D105002 75 TRANSDUCER PRESS 1 4 MNPT 1 PSI D104962 76 GASKET 2 8 OD EPDM 60 DURO EVO 559 GAS MAN D104190 77 BURNER INL HW79 399 AIR GAS D112959 78 BURNER PIP...

Страница 61: ...16 0 0 114 User data 2 1 0 Brian Brian 11 15 2017 10 10 2017 Updated wire colors AWG X1 1 2 3 4 120VAC L1 120VAC L2 Neutral Ground 240VAC Split Phase Customer Supplied X2 1 2 3 4 X3 1 2 3 4 CR1 A1 A2...

Страница 62: ...PUMP RELAY GAS VALVE RELAY POWER TO PUMP MAIN POWER X4 X3 X2 X1 X5 62 APPENDIX ADDITIONAL ELECTRICAL DRAWINGS MAIN POWER RELAY ASSEMBLY...

Страница 63: ...0 5152 53 54 55 56 X6 1 2 3 X7 1 2 X8 1 2 X9 1 2 3GRouter Protonode B A SG FG Port 2 CDB B OT A OT CAT5 RJ 45 If Equiped ToTerminals 13 14 17 On Nearest Appliance 05 12 05 2 Disconnect Box Belkin 5402...

Страница 64: ...ce is not performed warranty coverage may be voided Warranty information can be found on our website www hamiltonengineering com If you have any questions or comments please contact us at 800 968 5530...

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