Evo HW 79 Wiring diagram

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Installing, Operating & Maintaining
EVO 79–599 HIGH EFFICIENCY
WATER HEATERS AND HEATING BOILERS
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
instructions. If you can not reach your gas
supplier, call the re department.
If the information in this manual
is not followed exactly, a re or
explosion may result causing
property damage, personal
injury or death.
WARNING
New York Massachusetts SCAQMD CEC Listed
MEA 425-05-E Boilers: G1-06-06-24A Compliant Rule1146.2 California Energy Commission
Heaters: G1-06-06-24B
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.
EVO 299–599
300,000 BTU/hr
399,000 BTU/hr
630,000 BTU/hr
EVO 79–199.1
80,000 BTU/hr
136,000 BTU/hr
180,000 BTU/hr
199,000 BTU/hr
ANSI Z21.13-2014/CSA 4.9-2014
UL 795-2011/CSA 3.4
SCAQMD 1146.2

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Page 2
Throughout this manual you will see these
special attention boxes similar to this one,
which are intended to supplement the
instructions and make special notice of
potential hazards. These categories are in the
judgement of Hamilton Engineering, Inc.
USING THIS MANUAL
USING THIS MANUAL
Indicates a condition or hazard which
MAY cause severe personal injury,
death, or major property damage.
DANGER
Indicates a condition or hazard which
MAY cause severe personal injury,
death, or major property damage.
CAUTION
Indicates a condition or hazard which
MAY cause severe personal injury,
death, or major property damage.
WARNING
WARNING
• THE VENT SYSTEM IS RATED AND DESIGNED TO BE 2 PIPE SEALED COMBUSTION
ONLY, PVC SCH 40 OR CPVC SCH 40 OR 80 OR AL 29-4C STAINLESS VENTING FOR ALL
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 NFPA 54 AND/OR CAN/CGAB149
INSTALLATION CODES. STATE AND LOCAL CODES MIGHT ALSO APPLY TO
INSTALLATION.
• WHERE REQUIRED BY THE AUTHORITY HAVING JURISDICTION, THE INSTALLATION
MUST CONFORM TO THE STANDARDS FOR CONTROLS AND SAFETY DEVICES FOR
AUTOMATICALLY FIRED HEATERS, ANSI/ASME HEATER AND PRESSURE VESSEL CODE,
SECTION IV, ALONG WITH CSD-1.
• THE HEATER, GAS PIPING, WATER PIPING, VENTING AND ELECTRICAL MUST BE
INSTALLED BY TRAINED & QUALIFIED PERSONNEL FAMILIAR WITH INSTALLATION
PRACTICES, LOCAL CODE, AND LICENSING REQUIREMENTS.
• IF THE INFORMATION IN THESE INSTRUCTIONS ARE NOT FOLLOWED EXACTLY, A FIRE
OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR
DEATH.
• DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN
THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

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Page 3
Part 6 . . . . . . . . . . . . . . . . . . . . . . 38-40
START UP PROCEDURES
A Items to be checked before
lighting the EVO 38
B Lighting Instructions 38-39
C Operating Instructions 39
D Adjusting the Temperature
on the EVO Display 39
E Sequence of Operation 40
Part 7 . . . . . . . . . . . . . . . . . . . . . . . 40-47
SERVICING
A Servicing the EVO 40
B Placing EVO into Normal Operation 40
C Soft Lockout Codes 41
D Hard Lockout Codes 41-42
E Fault Causes 43-44
F To Turn Off Gas to Appliance 46
G Pump & Wiring Control 46
H Temperature Sensor Reading
Instructions 46
I EVO Sensor Resistance Table 47
Part 8 . . . . . . . . . . . . . . . . . . . . . . . 47-64
MAINTENANCE
A Maintenance Procedures 47
B Annual Inspection 48-52
C Condensate Cleaning Instructions 53
D Combustion Chamber
Coil Cleaning Instructions 54-55
E EVO Controls 56
F Coil Scaling Prevention Feature
(E-6 error codes) 57
G EVO 79-199.1 Parts Breakdown 58-60
H EVO 299 -599 Parts Breakdown 61-64
I Universal Wiring Diagram 65
Part 9 . . . . . . . . . . . . . . . . . . . . . . . 66-67
SPECIAL INSTALLATION REQUIREMENTS
A Installation Requirements
(Massachusetts) 66
B Installation at High Altitudes 67
Part 10 . . . . . . . . . . . . . . . . . . . . . . . . 67
WARRANTY INFORMATION
A Warranty Contact Information 67
TABLE OF CONTENTS
TABLE OF CONTENTS
Part 1 . . . . . . . . . . . . . . . . . . . . . . . 4-11
GENERAL INFORMATION
A How It Operates 4-5
B EVO Controls 6-8
C EVO Dimensions 9-10
D Pre-installation Requirements 10-11
E Pressure Relief Valve 11
Part 2 . . . . . . . . . . . . . . . . . . . . . . 12-13
ELECTRICAL
A Electrical Connection/Requirements 12
B Internal Wiring Connection 12-13
Part 3 . . . . . . . . . . . . . . . . . . . . . . 14-19
GAS CONNECTION
A Gas Connection 14
B Gas Piping 14
C Gas Tables 15
D Gas Valve Set Up 15-17
E Setting Maximum Load 17-18
F Setting Minimum Load 18
G Gas Conversion 19
H Gas Valve Replacement 19
Part 4 . . . . . . . . . . . . . . . . . . . . . . 20-28
VENTING
A Approved Venting Materials 20
B Venting the EVO 21-26
C Inlet Air Vent 27
D Venting Runs Exceeding Maximum
Combined Length 27
E Heater Removal from a
Common Vent System 27-28
F Condensate Requirements 28
Part 5 . . . . . . . . . . . . . . . . . . . . . . 29-37
PIPING
A Hydronic Heating Boiler Piping 29
B Boiler Schematic Drawings 30
C Fill & Purge Heating System 31
D Removing Air from Heat Exchanger 31
E Water Heating Piping 32
F Water Heater Schematic Drawings 33-37

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Page 4
GENERAL INFORMATION
PART 1. GENERAL INFORMATION
A. HOW IT OPERATES
The EVO product line is an extremely high efciency water heating product, requiring special venting and
condensate removal precautions. All high efciency condensing appliances will require more maintenance
(cleaning) than their non-condensing counterparts. Failure to do so may result in damage to the appliance that
is not covered under warranty. Failure to follow all of the instructions contained in this manual may also cause
premature product failure that may not be covered under warranty.
This appliance has built-in freeze protection, automatically activating the circulation pump when the internal
water temperature drops below 41°F. If the internal water temperature 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 primary controller (FMT 914) operates all functions of needed control and safety. It contains
sophisticated logic that allows it to operate at very precise temperatures while minimizing burner on/off cycling.
When multiple units are operated as a Cascade to handle a common load, the control logic contains the ability
to control all of the units as efciently as one. Cascade operation is a factory-installed and programmed option,
requiring a eld wiring connection between appliances for operation.
Looking at the controls on the front of the appliance,
1) POWER on/off switch
2) SETPOINT knob, temperature control (and fan speed control knob during service mode)
3) TEMPERATURE setpoint display
a. Temperature in °F, corresponding to the SETPOINT knob
b. Display will always read temperature setpoint unless there is a fault code displayed.
c. Cascade indicator light, found in the lower right hand corner of the Temperature display. This dot will
be ashing when this appliance is part of a properly-connected, commonly-controlled group of EVO
products and reading temperature sensors.
d. Display code, not ashing indicates a Soft Lockout
e. When this display is ashing a code, the appliance is in a Hard Lockout and the reset must be
pushed to re-start the appliance.
4) Green indicating light labeled BURNER ON; when lit, the burner is ring.
5) RESET button, used as described in 3e above, as well as to view sensors and set altitude
(see pages 46 & 64 respectively for details).
6) SERVICE port, used for connecting a computer to the appliance to download the service fault history, as
well as factory setting of control board parameters. There is a service button located just below the
service port that must be pressed with a pointed object to get to the service mode.

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Page 5
GENERAL INFORMATION
EXAMPLE: Water Heater Control
Controlling sensor
All of the following parameters are controlled by either a storage tank temperature sensor or the inlet temperature
sensor:
• Setpoint = Target Temperature (120°F) Low re only above this point
• Offset = Off Setpoint (3) = 123°F off
• Hysterese = On Setpoint (8) (120 + 3 - 8 = 115°F)
• Bandwidth = Modulation range (4) (120 - 4 = 116°F, modulation begins)
The heater turns on at 115°F and when the temperature reaches 116°F the ame will begin to modulate down
(approximately 25% of the modulation range per degree F of increase in this example) at 120°F, it will be at low
re and will remain there unless the temperature drops below 120°F and it will modulate back up. If it continues
to increase, it will shut down at 123°F.
Outlet sensor
Its purpose is twofold: rst stage as a high limit and second as a sensor for computing ∆T. Default water heater
settings are as follows:
• Setpoint = start of modulation (185°F)
• Offset = Off Setpoint (5°F) (185 + 5 = 190°F off)
There is a xed Manual Reset High Limit at 198°F (155°F and 210°F also available) on water heaters and
heating boilers.
A number of parameters must be programmed at the factory to provide proper operation and temperature
control, including:
• Controlling Sensor: Setpoint, Offset, Hysterese and Bandwidth.
• Controlling sensor is the inlet sensor for a stand alone water heater, outlet sensor for a stand
alone boiler or the remote 10k thermistor for either water heater or boiler any time one is
connected. Connection is automatically detected and control shifted to the remote sensor from
the internal sensor by the EVO Controller when a 10k sensor is connected to the appropriate
terminals.
• Secondary Sensor: Setpoint Outlet and Offset.
• Setpoint: desired operating water temperature (this is set by the end user)
• Offset: amount the temperature is allowed to go above Setpoint before nally shutting off
• Hysterese: amount the temperature is allowed to drop under Setpoint plus offset before the
appliance turns on
• Bandwidth: the range over which ame modulation occurs (this only takes place below Setpoint)
Modulation Range
Setpoint
Setpoint + Offset
Setpoint + Offset - Hysterese
Bandwidth
Burner On
Burner Off
115°
119°
120°
121°
122°
123°
124°
125°
126°
116°
118°
117°
Temperature
Low Fire

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Page 6
B. EVO CONTROLS
GENERAL INFORMATION
The following is an overview of the EVO controls. More detailed descriptions of EVO congurations can be found
in LIT91110 - FMT-914 Control Congurations.
Control Sensors - Control of the EVO will require the use of appropriate internal and external control
sensors (all 10k ohm):
• Flow - this is the internal leaving water from the heater/boiler.
• Return - this is the internal entering water to the heater/boiler.
• External - this is the storage tank sensor on water heaters and the common loop/low loss
header sensor on boilers.
• Indirect Sensor - this is the Domestic Hot Water tank sensor on a heating boiler application only.
• Outdoor - the is the sensor to be mounted outdoors for temperature reset control on a heating
boiler application only.
Pump Control - All water heaters and boilers are designed to operate with their own individual pump that
will be controlled, on/off, by the EVO controller. The controller runs the pump for a xed period of time
after the end of a burn cycle and uses the combustion air fan as the cooling medium to ONLY cool the
heat exchanger. This is accomplished by monitoring the inlet and outlet water temperature sensors and
running the fan until they are within a pre-set range.
Cascade Control - When multiple units are operated as a Cascade system to handle a common
load, the EVO controller contains the ability to control up to 8 burners as efciently as one.
Common Venting - When units are installed as a Cascade system and a factory-supplied common venting
manifold is used, the software contained in the controller provides for accurate, fail-safe control of all
units in the Cascade while using a single air supply and single exhaust, for up to (8) burners. In addition
to this software, hardware that is standard in each unit, makes venting of multiple units in a positive pressure
venting system a reality.
Control of ring rate - The EVO controller contains sophisticated logic that allows it to operate at very
precise temperatures while minimizing burner on/off cycling. Whether the temperature setpoint is manually
set, sent via BMS as 0 – 10 VDC signal, or calculated via the outdoor reset function, precise temperatures
are the standard. The difference between the temperature set-point and the water temperature sensed
at the control sensor and how quickly the temperature is moving to or away from that desired water
temperature are the basis for the control response.
Domestic Water Heating (DHW) - This controller is the only one of it’s kind in use in North America
that contains separate software for DHW and Central Heating. Safeties, control response and other
operational considerations are unique to DHW applications, including concerns of scaling due to poor
water conditions. The EVO controller was designed from the ground up with this application in mind.
It is recommended to use an external sensor located in the storage tank for control in DHW applications.
If an external temperature sensor is not used, the EVO will be controlled by its own inlet (Return) sensor and
the water heater pump must run constantly.

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Page 7
B. EVO CONTROLS CONT.
GENERAL INFORMATION
Central Heating - The EVO controller has many built-in functions for precise control in Central Heating
applications. The controller can operate on its own internal Flow (outlet) sensor, however the preferred
method is to use an External Sensor connected to the Lead Boiler. If the External Sensor is not
employed, the boiler(s) will need to have a constant ow of water so that the internal sensors can accurately
detect the loop temperature.
When the External sensor is installed in the main building loop or a Hamilton System Separator (low loss header),
the boiler system operates at peak efciency, reducing short-cycling and maintaining a constant loop temperature.
The External Sensor must be installed in a location that has good water ow - avoid positions where the sensor
will be located in stagnant ow areas or in the near boiler piping. See LIT91110 - FMT-914 Control Congurations
for suggested locations.
In a Central Heating application, the EVO controller can utilize an outdoor thermistor for outdoor reset (without
the need for an external controller), remote setpoint control from a BMS or external controller (0 - 10 VDC), and
indirect DHW priority. See below for additional details on these features.
Outdoor Reset - The EVO controller will automatically operate while in the Central Heating mode, utilizing
Outdoor Reset. When a 10K ohm thermistor is connected to the EVO, the controller will automatically
change the temperature setpoint to a calculated value based on the programmed outdoor reset curve.
The setpoint selected by the outdoor reset curve can be shifted (parallel shift) up to 36°F above or below
by adjusting the temperature control knob on the display.
BMS 0 - 10VDC control - The range of 0 – 10 volts corresponds directly to the temperature range imbedded
in the control software. Factory default for heating boilers is 50°F – 194°F. With the standard parameter
sets, the following would be true:
0 - 0.9 volts = boiler(s) off
1 volt = 50°F
4 volts = 98°F
7 volts = 146°F
10 volts = 194°F
(each volt = 16°F)
Voltage can be sent in any value between 1 and 10 and the temperature set point will be the exact value that
corresponds to that voltage. Below 1 volt, there will be considered no heat demand.
Note: If another type of heat demand device is connected to the EVO, such as a room thermostat (or the
jumper wire factory shipped in place), the controller will revert to that as it’s control point when the voltage is
less than 1. If the 0–10 VDC signal is lost from the external source, such as a BMS, the control will revert to
its maximum set point if there is a jumper or other closed thermostat connected to the “Room Thermo-
stat” terminals. If this is not desired and heat with some form of control is desired, a relay may be used.
The relay coil can be energized from the control source (i.e. BMS) and the common and NC contacts
from the relay can be connected to the room thermostat terminals and an outdoor air sensor connected
to the appropriate point on the EVO terminal strip. If power is ever lost from the control source, the relay
will de-energize and close the room thermostat terminals, thus activating the outdoor reset (see above
for control).

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Page 8
B. EVO CONTROLS CONT.
GENERAL INFORMATION
Further notes to the use of 0–10 VDC as a control:
• Room thermostat jumper must be removed—if it is not, it will re based on setpoint when there
is less than 1 volt
• Red dial must remain in the maximum position (all the way to the right) If it is not turned all the way
to the right, it’s corresponding setpoint becomes the maximum the 0–10 volt signal will go to,
regardless of the voltage supplied.
• 0 VDC–0.9 VDC results in no call for heat
• 1 VDC results in minimum set point, this should always be programmed to the minimum water
temperature desired when using a BMS system.
• 10 VDC results in maximum set point, this should always be programmed to the maximum
water temperature desired when using a BMS system. Voltage can be sent in any value between
1 and 10 and the temperature set point will be the exact value that corresponds to that voltage.
Below 1 volt, there will be considered no heat demand.
Production of Indirect Domestic Hot Water - this controller can also provide for control of split loads,
Central Heating and Domestic Hot Water, via an additional pump or diverting valve with priority for DHW,
a user selectable option. It can also control the system pump or signal to a zone controller, if required.
See LIT91110 - FMT-914 Control Congurations for suggested piping diagrams and details.
The EVO control system offers the ability to automatically provide DHW from a stand alone or group of Cascaded
Heating Boilers. To do this properly, a 10k ohm thermistor or aquastat, which senses the DHW tank water temperature,
must be connected to the appropriate terminals on the EVO.
The default control parameters provide priority for DHW production. On a call for heat from the DHW tank,
the EVO will:
• Switch on if there is no current heat demand
• Drop power to the system pumps, if energized through relay and EVO controller
• Energize indirect DHW pump or 3-way valve
• Change boiler water temperature setpoint to preset parameter
When the DHW load is satised, the indirect DHW pump will run for an additional minute (the boiler will be off)
as a cool down cycle, then the boiler will resume the state and water temperature it was at prior to the DHW call
for heat.

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Page 9
GENERAL INFORMATION
C. EVO DIMENSIONS
(TABLE 1-2) EVO INFORMATION
*At 97% thermal efciency with 86oF incoming water to heat exchanger
**At 95% thermal efciency with 140oF incoming water to heat exchanger
Model Input
BTU/hr
Water Heater*
Output
BTU/hr
Boiler**
Output
BTU/hr
GPH
Recovery
@ 100˚F∆T
GPH
Recovery
@ 80˚F∆T
GPH
Recovery
@ 60˚F∆T
Water Flow Rate &
Pressure Drop
DWH† Heating
Shipping
Weight
HW 79 80,000 up to 77,600 up to 76,000 93 116 155 [email protected]' [email protected]' 66 lbs
HW 129 136,000 up to 132,890 up to 130,150 160 199.1 265 [email protected]' [email protected]' 66 lbs
HW 179 180,000 up to 174,829 up to 171,224 210 262 349 9.9@21.' [email protected]' 75 lbs
HW 199.1 199,999 up to 193,999 up to 189,999 233 291 388 [email protected]' [email protected]' 75 lbs
HW 299 300,000 up to 291,000 up to 285,000 360 450 600 [email protected]' 1[email protected]' 172 lbs
HW 399 399,999 up to 387,999 up to 379,999 466 582 776 [email protected]' [email protected]' 204 lbs
HW 599 630,000 up to 611,100 up to 598,500 734 917 1223 [email protected]' [email protected]' 260 lbs
3/4"=1' Reference dimensions are ± 10%
All dimensions are ± 1"
Custom
Dwg No.
Customer / Job name:
Scale:
Description: Drawn/
Revised by:
Checked/
Apv.by:
Revision:
MM/DD/YY
Date:
Condensate Trap
Cleaning Point
Gas (D)
Gas (D)
Inlet (B)
Inlet (B)
Air In (A)
Air In (A)
Left View
Outlet (C)
Outlet (C)
Exhaust
Out (A)
Exhaust
Out (A)
Relief Valve
Relief Valve
Condensate Waste
Condensate Trap
Cleaning Point
Front View
3/4"=1' Reference dimensions are ± 10%
All dimensions are ± 1"
Custom
Dwg No.
Customer / Job name:
Scale:
Description: Drawn/
Revised by:
Checked/
Apv.by:
Revision:
MM/DD/YY
Date:
Condensate Waste
Air Vent
Air In (A)
Exhaust
Out (A)
Front View
Condensate Waste
Condensate Waste
Condensate Trap
Cleaning Point
Gas (D)
Inlet (B)
Outlet (C)
Relief Valve
Condensate Waste
Air Vent
Condensate Trap
Cleaning Point
Gas (D)
Inlet (B)
Air In (A)
Left View
Outlet (C)
Exhaust
Out (A)
Relief Valve
(TABLE 1-1) EVO DIMENSIONS
Model Width HeighttDepth A B C D
79–199.1 16" 20.5" 12" 3" 1" 1" 0.75"
299 19" 33" 19" 4" 1.5" 1.5" 0.75"
399 19" 33" 19" 4" 2" 2" 0.75"
599 19" 35" 26.5" 5" 2" 2" 1"

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Page 10
GENERAL INFORMATION
D. PRE INSTALLATION REQUIREMENTS
The EVO models 299–599 are designed to be installed using a factory designed
and supplied rack or frame (see Figure 1-3 for details). Models 79–199.1 may also
be installed using an optional wall bracket. If the wall bracket is used, care must
be exercised to insure that the wall structure is sufcient to support the
weight of the connected load (see weights in Table 1-2, pg.9). Consult factory
for details of wall mount bracket. It can be installed in alcoves, basements, and
utility rooms, as well as standard equipment rooms. Choose a location for your
EVO, centralized to the piping system, along with consideration for Electrical
(Part 2, Gas Connection (Part 3), Venting (Part 4), and Condensate Drain (Part
4, Section F).
The EVO heat exchanger must be level as installed, and the mounting surface
must be designed to support the weight (see previous page, Table 1-2 for
weights). Be sure the appliance is adequately secured to the mounting surface.
The front cover is secured by a threaded screw and two clasp style latches; it
can only be installed one way. When removing the front cover of the EVO
3/4"=1' Reference dimensions are ± 10%
All dimensions are ± 1"
Custom
Dwg No.
Customer / Job name:
Scale:
Description: Drawn/
Revised by:
Checked/
Apv.by:
Revision:
MM/DD/YY
Date:
(FIGURE 1-3)
EVO MOUNTING DETAIL
(FIGURE 1-2) EVO CLEARANCES
RECOMMENDED SERVICE CLEARANCES
(NOTE: The EVO is rated at zero
clearance to combustibles.)
3/4"=1' Reference dimensions are ± 10%
All dimensions are ± 1"
Custom
Dwg No.
Customer / Job name:
Scale:
Description: Drawn/
Revised by:
Checked/
Apv.by:
Revision:
MM/DD/YY
Date:
Zero Clearance
from back of unit
to wall
18" Clearance
from bottom of unit
24" Clearance from front of unit
12" Clearance
from top of unit
3" Clearance
from side of unit
unit, you must make sure all electric power to the appliance is turned off. Then remove the screw at the
bottom of the panel, undo the latches and remove the cover (see Figure 1-4 on the next page).
If the EVO is set up for liqueed petroleum (LP) gas, some geographic areas follow the Uniform Mechanical
Code, section 304.6, “Liqueed petroleum gas burning appliances shall not be installed in a pit, basement or
similar location where heavier-than-air gas might collect. Appliances so fueled shall not be installed in a below
grade under-oor space or basement unless such location is provided with an approved means for removal
of unburned gas.”
Note: A water chemistry analysis should be performed prior to any installation. If the water quality
exceeds any of the following levels, then a water chemistry analysis must be performed:
• Water hardness can be no more than 12 grains (205 ppm or mg/l)
• TDS (total dissolved solids) can be no more than 450 ppm or mg/l
• PH - below 6.5 or above 7.5
For total combined hardness over 15 grains (250 ppm or mg/l) or longer pipe lengths, contact Hamilton
Engineering for correct pump sizing. Combined, the hardness and TDS can be no more than 450 ppm.
Our internal term for this is the TCH (Total Combined Hardness).