Hamilton Engineering EVO 299 Manual

ADDENDUM TO LIT91127 & LIT91146
EVO 129–599
REQUIRED MAINTENANCE PROCEDURES
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.
34000 Autry Street, Livonia, MI 48150 • 800.968.5530 • Fax [phone] • www.hamiltonengineering.com • LIT91178 REV 5/2017
EVO DUO
300,000 BTU/hr
399,999 BTU/hr
630,000 BTU/hr
INNOVATIVE CONDENSING TECHNOLOGY
By Hamilton Engineering, Inc.
EVO 299–599
300,000 BTU/hr
399,000 BTU/hr
630,000 BTU/hr
EVO MICRO
80,000 BTU/hr
136,000 BTU/h
180,000 BTU/h
199,000 BTU/h
INNOVATIVE CONDENSING TECHNOLOGY
By Hamilton Engineering, Inc.
EVO 129–199
136,000 BTU/hr
180,000 BTU/hr
199,000 BTU/hr

34000 Autry Street, Livonia, MI 48150 • 800.968.5530 • Fax [phone] • www.hamiltonengineering.com • LIT91178 REV 5/2017
Page 2 of 9
INTRODUCTION
All high efciency condensing appliances will require more regular 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.
Periodic maintenance should be performed at least once a year by a qualied service technician to ensure that all the equipment
is in safe, efcient operation. Failure to do so may eliminate warranty coverage. In the rst year of operation, it is highly
recommended that 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 void warranty. Assuming
no cause for excessive fouling is found, then the period of months from initial start up that it was found that cleaning was
required, shall become the required future minimum cleaning interval, but at no time should it exceed 12 months. The owner
MUST make necessary arrangements with a qualied heating contractor for proper maintenance of the heater. Installer must
also inform the owner that the lack of proper care and maintenance of the heater may result in a hazardous condition and
lack of warranty coverage. The installer should discuss the contents of the User’s Information Manual with the owner.
An inspection should cover, at a minimum, the following areas:
• Download and review operating hour data and fault history
 •Inspectallttings,controlsandconnectionsforleaks,damage,orfouling
• Fire side:
Heat exchanger
Burner and ignitor
Burner door and rear wall insulation
• Drain system components:
Hoses & clamps
Trap assembly
Condensate neutralizer
• Test all safeties and operating controls
 •Watersidetemperaturerise(∆T)test
DATA DOWNLOAD
Alwaysretrievefaulthistoryandpoweronhoursfromthecontrolboardrst,usingyourlaptoporPDAandtheSITcableand
software.Besuretousetheproperversionsoftwareandcommunicationcable,thensavetheleandnameappropriately
for future reference. Should the servicing contractor not have the proper software, cables, and training to do this, have them
contact the factory or their local distributor.
INSPECTION AND CLEANING (photos illustrating each step follow sets of instructions)
Caution: Before removing the door of the appliance, switch off the electrical power supply to it.
 •Removethefrontcoverandcheckthesensors,owswitch,allpipes,linesandconnections,
 andtheheatexchanger(top,bottom)fortracesofwaterandwaterleakage.
• Inspect the top of the casing and/or the top of the appliance for water leakage or traces of
 waterfromtheairsupplypipeortheairvent(ifapplicable).
• Inspecttheowswitch;theappliancemustrstbe drained by closing the inlet and outlet valves on
each appliance. Then, by opening the drain on the ball valve and the relief valve, the appliance will drain.
Isolation and drain
valve appliance outlet
Isolation valve for pump
& appliance outlet
Relief valve - check operation
and open to drain unit
ANNUAL INSPECTION (See LIT91179 Maintenance Checklist for required tools and materials)

FLOW
SWITCH:
Check paddle for
fouling and free
movement by
spring!
34000 Autry Street, Livonia, MI 48150 • 800.968.5530 • Fax [phone] • www.hamiltonengineering.com • LIT91178 REV 5/2017
Page 3 of 9
 •Dismantletheburnerunit:removethe(6)6mmnuts(witha10mmsocket),theignition
cable, the power and speed control plugs, and the ground wire from the fan, and
remove the burner/fan unit from the heat exchanger and cabinet.
• After the burner door is removed, it should be thoroughly inspected
before being put back into service. There are two gaskets on the
 burnerdoor;therstistheinnerropegasket,whichispermanentlyafxedtotheburner
 door.Ifthisgasketiscompletelycompressed(havingnosealingability),thedoormust
 bereplaced.Thesecondgasketisontheperimeterandismadeofrubber;thisgasket
is easily replaced, and comes as a standard part of a maintenance kit (and should always be replaced
during the annual maintenance procedure. Note: Over-tightening the M6 nuts may cause the threaded
rods on the front of the heat exchanger to break! If excess resistance is encountered when installing
a M6 nut, discard that nut and use one of the spares shipped with the unit. The maximum torque for
assembling a burner door nut is 3.7 ft-lb or 44.4 in-lb. Use a torque wrench suitable for this torque
range to tighten the nuts.
•Removeandinspecttherearberboard.Ifanyresistanceisencounteredwiththeremovalofthescrew
 securingtheberboardinplace,donotexertundoforce;breaktheberboardouttoprovideaccesstothe
screw. Apply penetrating oil to the screw, let it sit, then remove. See photos below for details. Replace only
 aftercleaningprocedure.Useanewberboardifmoisturehasfouleditorifthereisanyphysicaldamage
 preventingitfromprotectingtherearwall,suchascracksorwarping.Warpedberboardswillallowtheback
 walltooverheat,thiscouldleadtoabreachofthebackwall.Thiswillalsocausealossofefciencyanda
rise in stack temperature. Note: Failure to replace front and rear berboard when damaged may result
in irreparable damage to the appliance!
Complete burner,
door & fan assembly
removed for inspection
Both of
these
must be
replaced!
ANNUAL INSPECTION CONT.

34000 Autry Street, Livonia, MI 48150 • 800.968.5530 • Fax [phone] • www.hamiltonengineering.com • LIT91178 REV 5/2017
Page 4 of 9
 •Checkthere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owoftheproductsofcombustion.
• Use inspection mirror to check all heat pass 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owtothecondensatedrainpoint.
• If surface or coil gap fouling still exists after the above measures have been
taken, the use of a non-acid based cleaning solution, such as Fernox F3, is
acceptable. Rinse entire heat exchanger thoroughly after cleaning
procedure is complete.
(See complete cleaning instructions on page 53-55)
•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ame;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residecomponents.
Burner door refractory
must sit rmly against
burner door and must
not have any cracks,
water damage, or gouges.
If any of these exist, it
MUST be replaced.
Cleaned heat exchanger -
prior to rear wall installation
Cleaned heat exchanger -
after rear wall installation
Burner & door assembly -
priortoberboardinstallation
ANNUAL INSPECTION CONT.

334000 Autry Street, Livonia, MI 48150 • 800.968.5530 • Fax [phone] • www.hamiltonengineering.com • LIT91178 REV 5/2017
Page 5 of 9
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signicantnoisesfromthefanandpump.Also,inspect
for leaks at the pump connections.
• Press the reset button from the home screen to access the sensor readings, and record each reading,
making sure that all sensors and thermometers are reading the same, with the heat off.
 •Firetheapplianceonmaximumoutputfor5minutes,inordertocheckthe∆Tfromtheinletsensorto
the outlet sensor.
  -Ifthe∆Treadingisoutofdesignrangebymorethan10%orthereisanE6erroronthe
  display,refertocoilcleaninginstructionsbelow.Record∆Ttotrackanyincreasesfromone
year to the next.
• Fire the appliance on maximum output, and measure and adjust the CO2percentage as required.
• Fire the appliance on minimum output, and measure and adjust the CO2percentage as required.
 •IfthereareanunusualnumberofF5orF6faultsorifcombustionisoffsignicantly,gassupply
 pressuremustbeveriedatstatic(noload)andfullbuildingloadconditions.
 •SeeTable3-3,Page17forspecicsettings.
 •Inspectintakeandexhaustscreensattheterminationpointforsignsofcontamination(i.e.leaves,twigs,etc).
 •Adifferentialpressure(∆P)readingshouldbetakenacrosstheexhaustandinletairconnectionpoints
 ofeachappliancetoconrmthatitisbelowthemaximumshownbelow.
NOTE: The inlet air pressure should be negative.
MODEL AIR PRESSURE
(∆P) MODEL AIR PRESSURE
(∆P)
HW129 < .6” wc HW399 < 1” wc
HW179 < .96” wc HW599 < .86” wc
HW199.1 < .68” wc HWH 1499-1999 < .8” wc
Hamilton EVO Products
Flow and Pressure Drop (GPM Feet of Head)
Design
HW 79 - 129 (.8) HW 179 - 199.1 (.8) HW 299 HW 399 HW 599 HW 1499 HW 1999
Flow Rate GPM Head GPM Head GPM Head GPM Head GPM Head GPM Head GPM Head
2.2 1.8 3.5 2.1 6.6 3.4 13.2 4.8 22.0 5.9 52.8 6.3 70.4 6.2
3.3 4.6 4.4 3.9 8.8 6.0 15.4 6.5 24.2 7.2 57.2 7.4 76.3 7.4
Hydronic 4.4 (4) 7.9 6.6 (5) 7.9 11.0 9.3 17.6 8.5 26.4 9.4 61.6 8.6 82.2 8.6
5.3 11.6 7.7 12.5 13.2 13.4 19.8 10.8 30.8 11.6 70.5 11.2 99.8 12.6
6.2 15.4 8.8 15.2 15.4 18.3 22.0 13.4 35.2 15.2 79.3 14.2 111.5 15.8
DHW - direct 6.6 17.7 9.9 17.7 16.5 21.1 26.4 19.2 39.6 21.3 92.5 19.3 123.3 19.3
7.7 24.1 11 21.5 17.6 23.9 30.8 26.2 41.8 21.4 96.9 21.2 129.2 21.2
8.8 31.5 12.1 29.5 19.8 30.2 33.0 30.1 44.0 23.7 101.3 23.1 135.0 23.1
Model
BTU/hr.
Input
Minimum
Hydronic
Flow
∆P at
Minimum
Flow
Rate - ft.
of head
Hydroni
c Pipe
Size
DHW
Pipe
Size
HWH 79 80,000 2.23 3.3 1" 34.6 19.2 1"
HWD 79 80,000 23.5 13.1
HWH 129 136,300 3.64 3.5 1" 58.9 32.7 1"
HWD 129 136,300 40.1 22.2
HWH 179 186,600 5.06 3.3 1" 53.7 29.8 1"
HWD 179 186,600 36.6 20.3
HWH 199.1 199,999 5.63 3.5 1" 57.6 32.0 1"
HWD 199.1 199,999 39.2 21.8
HWH 299 300,000 8.45 4.9 1.5" 51.8 28.8 1.5"
HWD 299 300,000 35.3 19.6
HWH 399 399,999 11.31 3.5 1.5" 43.2 24.0 2"
HWD 399 399,999 29.4 16.3
HWH 599 630,000 17.74 4.9 1.5" 45.3 25.2 2"
HWD 599 630,000 30.9 17.1
HWH 1499 1,500,000 42.13 5.2 2.5" 46.3 25.7 2.5"
HWD 1499 1,500,000 31.5 17.5
HWH 1999 1,999,999 58.45 5.2 2.5" 46.3 25.7 2.5"
HWD 1999 1,999,999 31.5 17.5
Design ∆T
Hydronic @ 95%
efficiency
°F °C
Design ∆
T
DHW @ 97%
efficiency
°F °C
Effective 11/2007 - Added minimum flow and pressure drop 3.09
LIT 91149
34000 Autry Street, Livonia, MI 48150 • 800.968.5530 • Fax [phone] • www.hamiltonengineering.com • LIT91149 REV 4/2009
ANNUAL INSPECTION CONT.

34000 Autry Street, Livonia, MI 48150 • 800.968.5530 • Fax [phone] • www.hamiltonengineering.com • LIT91178 REV 5/2017
Page 6 of 9
Trytokeepthemeasuringhoseat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
P1A = -0.32” wc
P1F = 0.4” wc
Then the total pressure drop is:
∆Ptotal=-(P1A)+P1F=-0.32+0.4=0.72”wc
Calculations are done with:
•Allboilersathighre
•Watertemperature160/180ºF(givesthehottestue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 appliances.
Use of a static pressure
tip for measurement is
also recommended
• A pH test must be performed at the exit point of the condensate neutralizer with litmus paper to test for
acidity. pH level should be within 6.6-7.0. If the pH is less than 6.6, replace neutralizing medium.
 •Checkingtheminimumandmaximumsettingsonthedisplaymustbeperformedasanalcheck.
 •Allndingsandconcernsshouldbediscussedwiththeapplianceowneraftertheinspectioniscomplete.
ANNUAL INSPECTION CONT.

34000 Autry Street, Livonia, MI 48150 • 800.968.5530 • Fax [phone] • www.hamiltonengineering.com • LIT91178 REV 5/2017
Page 7 of 9
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.
  2)Placeabucketunderthecondensatetrap.Usecautionwhenremovingtheclean-outcap,as
the trap is full of condensate and it may be hot.
  3)Removethecondensateclean-outcap,andbesurethe
bucket is under the open drain trap assembly to catch
the debris and water.
  4)Rinseouttheclean-outcapinasinktoremoveanydirtorbuildupthatmayhaveaccumulated.
  5)Condensatedrainassemblyshouldnowbecheckedfornon-restrictedowthroughoutthe
entire assembly.
  6)Reinstalltheclean-outcaponthecondensatetrap.
  7)TurnonthepowertotheEVO.
  8)Makesurethehosefromthecondensatetrapisnotsubmergedtoofarintotheneutralizer,
there should be an air gap between the highest level of condensate and the outlet hose from the trap.
  9)Monitorthecondensatedrainuntilowhasbeenestablished.
CONDENSATE TRAP CLEANING INSTRUCTIONS

INSTALLATION OF THE BURNER DOOR DURING SERVICING
34000 Autry Street, Livonia, MI 48150 • 800.968.5530 • Fax [phone] • www.hamiltonengineering.com • LIT91178 REV 5/2017
Page 8 of 9
Proper precautions must be taken when installing the EVO burner door. Faulty installation or using a door
in need of replacement risks leakage of combustion products, or further, a damaged heat exchanger that
will not be covered under warranty.
Any time the burner door is removed, it should be thoroughly inspected before being put back into
service.Therearetwogasketsontheburnerdoor;therstistheinnerropegasket,whichispermanently
afxedtotheburnerdoor.Ifthisgasketiscompletelycompressed(havingnosealingability),thedoor
mustbereplaced.Thesecondgasketisontheperimeterandismadeofrubber;thisgasketiseasily
replaced and comes as a standard part of the maintenance kit (and should always be replaced during the
annualmaintenanceprocedure).Tolimitrisks,thefollowinginstructionsmustbeadheredto.
PROPER PROCEDURE
Before installing a burner door, the two gaskets and the burner door refractory must to be checked for damage or
deteriorationandproperplacement(rubbergasketandrefractory);oncethisinspectioniscompleted,theburnerdoorcan
be mounted with the six M6 nuts. Please note: Over-tightening the M6 nuts may cause the threaded rods on the
front of the heat exchanger to break! If excess resistance is encountered when installing an M6 nut, discard that nut
and use one of the spares shipped with the unit.
The maximum torque for assembling a burner door nut is 3.7 ft-lb or 44.4 in-lb
Use a torque wrench suitable for this torque range, to tighten the nuts.
M6 nuts and thread studs

After starting up the unit:
To limit the risk of leaking combustion products, a leak test of the burner door gaskets with a hand held
combustiongasleakdetector(sniffer)mustbedone.
See next page for detailed photos of burner door and gasket conditions.

34000 Autry Street, Livonia, MI 48150 • 800.968.5530 • Fax [phone] • www.hamiltonengineering.com • LIT91178 REV 5/2017
Page 9 of 9
INSTALLATION OF THE BURNER DOOR DURING SERVICING
New Burner Door
Rope gasket in good condition
Rope gasket raised above door surface (good!)
Damaged Burner Door
Damaged rope gasket—will not seal properly
Rope gasket at or below door surface (bad!)