Hamilton Engineering EVO Plus Series Wiring diagram

INSTALLING, OPERATING & MAINTAINING
EVO 299.2/.3–599.2/.3 High Eciency
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:
• 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.
If the information in this 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 Rule1146.2 California Energy Commission
ANSI Z21.13-2014/CSA 4.9-2014
UL 795-2011/CSA 3.4
SCAQMD 1146.2
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.

2USING 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 judgement
of Hamilton Engineering Company, Inc.
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.

3
TABLE OF CONTENTS
TABLE OF CONTENTS
USING THIS MANUAL ..................................................... 2
TABLE OF CONTENTS.......................................................3
PART 1. GENERAL INFORMATION............................... 4
A. How It Operates...........................................................................4
B. Glossary........................................................................................... 6
C. Dimensions.............................................................................. 7–8
D. Pre Installation Requirements......................................... 8–9
E. Pressure Relief Valve.................................................................9
PART 2. ELECTRICAL ..................................................... 10
A. Electrical Connection/Requirements...............................10
B. Internal Wiring Connection ...........................................10–11
PART 3. GAS CONNECTION...........................................12
A. Gas Connection And Inspection ......................................... 12
B. Gas Piping..................................................................................... 12
C. Gas Tables..................................................................................... 13
D. Gas Valve Setup................................................................. 13–14
E. Setting the Maximum Load .................................................15
F. Setting the Minimum Load................................................... 16
G. Gas Conversion .......................................................................... 17
H. Gas Valve Maintenance/Replacement ........................... 17
PART 4. VENTING ........................................................... 18
A. Approved Venting Materials................................................18
B. Venting the EVO............................................................... 19–24
C. Inlet Air Vent............................................................................... 25
D. Venting Runs that Exceed
Maximum Combined Length.............................................. 25
E. Heater Removal From An Existing
Common Vent System..................................................25–26
F. Condensate Requirements.................................................. 26
PART 5. PIPING................................................................27
A. Hydronic Heating Boiler Piping .........................................27
B. Boiler Schematic Drawings................................................. 28
C. Fill & Purge Heating System .............................................. 29
D. Removing Air From the Heat Exchanger...................... 29
E. Water Heating Piping ............................................................30
F. 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 Temperature on the EVO Display........37
E. Sequence of Operation.......................................................... 38
PART 7. SERVICING ........................................................38
A. Servicing The EVO................................................................... 38
B. Placing the EVO Into Normal Operation ....................... 38
C EVO Soft Lockout Codes ...................................................... 39
D. EVO Hard Lockout Codes......................................................41
E. To Turn O Gas to the Appliance...................................... 42
F. Pump & Wiring Control......................................................... 42
G. To Turn O Gas to the Appliance...................................... 42
H. Status Readings........................................................................ 43
I. EVO Sensor Resistance Table ............................................ 43
PART 8. MAINTENANCE...............................................44
A. Periodic Maintenance of Heater and Inspections
B. Annual Inspection........................................................... 45–49
C. Condensate Trap Cleaning Instructions.........................50
D. Combustion Chamber Coil
Cleaning Instructions ..................................................... 51–52
E. EVO Controls.............................................................................. 53
F. Coil Anti-Scaling Prevention Feature..............................54
PART 9. SPECIAL INSTALLATION REQS...................55
A. Installation Requirements—Massachusetts ............... 55
B. Installation At High Altitudes .............................................. 56
PART 10. PARTS BREAKDOWN.......................... 5760
APPENDIX. ADDL ELECTRICAL DRAWINGS .......... 61
Main Power & Relay Assembly and
Cascade Wiring for EVO............................................................... 61
Main Power & Relay Assembly ............................................... 62
Cascade Box with 3G Router..................................................... 63
PART 11. WARRANTY INFORMATION......................64
A. Warranty Contact Information .......................................... 64

4PART 1. GENERAL INFORMATION
PART 1. GENERAL INFORMATION
A. HOW IT OPERATES
The EVO product line is an
extremely high eciency water
heating product, requiring special
venting and condensate removal
precautions. All high e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
the HOT™ BCB and BDB boards
operate all functions of needed
control and safety. It contains
sophisticated logic that allows it to
operate at very precise temperatures
while minimizing burner on/o
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 eciently as one.
Cascade operation is a factory-
installed and programmed option,
requiring a field wiring connection
between appliances for operation.
BCB=
the internal Boiler Control Board.
BDB =
the Boiler Display Board;
human interface.
CCB =
the Cascade Control Board,
located in the external box.
CDB =
the Cascade Display Board, human
interface located in the face of the
external box.

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

6
B. GLOSSARY
PART 1. GENERAL INFORMATION
APS
Air pressure switch
BCB
Boiler Control Board
BDB
Boiler Display Board
Blocking
Limit situation is touched, boiler OFF;
when the safe situation is restored, boiler On.
CCB
Cascade Control Board
CDB
Cascade Display Board
CH
Central Heating
Condensate
Water vapor generated as a product of combustion,
which has a low pH.
DHL
Double High Limit
iDHW
Domestic Hot Water
Diverter valve
Motorized valve with spring return
DHW
Direct Hot Water production (instantaneous)
Hard Lock Out (HLO)
A significant error or issue with the appliance or system,
such as multiple failures to light or an unsafe pressure
dierential. An error code at this level will trigger a shutdown
of the aected appliance(s). Service or repair is required.
HLO
Hard Lock Out—Manual needed to energize the boiler
HMI
Human Machine Interface
Hysterese
Blocking set temperature+ oset temperature—
hysterese is starting temperature for the boiler.
ICM
Interface Cascade Manager (with or without WiFi)
Indirect Tank
Sanitary hot water tank with a built in heat exchanger
INI
Baseline data initialization, runs by default every 14 days
Lead-lag system
If plant production is operating heavily, the lead-lag
system will bring in the secondary boilers to help spread
out the load. When the lead-lag system senses that
production has dropped o, it then shuts those secondary
boilers down again.
Modbus
For Ethernet or RS232 or RS485 bus system for Lead and
Leg communication
Oset
Overriding temperature above set blocking: boiler OFF
PAVO
Zone controller
PCB
Printed circuit board—burner control board
Soft Lock Out (SLO)
Manual or App Rest needed to energize the boiler
Tank
Sanitary Hot Water Tank without internal Heat exchanger
3-way-valve
Motorized valve: turning to the right and to the left
Par
Parameter
n.a.
Not applicable. Constant value.
TBD
To be defined
Z-INI
First INI process

7
C. DIMENSIONS
PART 1. GENERAL INFORMATION
TABLE 12 EVO INFORMATION
*At 97% thermal eciency with 86oF incoming water to heat exchanger
**At 95% thermal e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 299 300,000 up to 291,000 up to
285,000 360 450 600 16.5@22.9' 11.0@9.3' 172 lbs
HW 399 399,999 up to 387,999 up to 379,999 466 582 776 26.4@20.3' 17[email protected]' 204 lbs
HW 599 630,000 up to 611,100 up to
598,500
734 917 1223 39[email protected]' 26.4@9.4' 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 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
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"

8PART 1. GENERAL INFORMATION
FIGURE 12 EVO 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:
D. PRE INSTALLATION REQUIREMENTS
C. DIMENSIONS (continued)
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).
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 unit, you must
make sure all electric power to
the appliance is turned o. 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 liquefied
petroleum (LP) gas, some geographic
areas follow the Uniform Mechanical
Code, section 304.6, “Liquefied
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-
floor 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).
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
RECOMMENDED SERVICE CLEARANCES
FIGURE 13 
EVO MOUNTING DETAIL

9
PART 1. GENERAL INFORMATION
D. PRE INSTALLATION REQUIREMENTS (continued)
This unit is supplied with a relief
valve sized in accordance with ANSI/
ASME Heater and Pressure Vessel
Code, Section IV. The relief valve is
installed near the hot water outlet.
If the valve supplied is replaced,
the pressure rating of the valve
must not exceed the listed working
pressure of this appliance, and
must be rated to the proper BTU/
hr capacity of the water heater. Do
not, under any circumstances,
thread a cap or plug into the relief
valve! Explosion, serious injury or
death may result! To prevent water
damage, the relief valve piping must
be directed to the floor or an open
drain, but not connected directly.
There must be a 6” space between
the outlet of relief valve piping and
drain or floor. Do not hook up to drain
system directly without an air gap.
Protect from freezing. Place no other
valve between the relief valve and
the unit. Do not install any reducing
couplings or other restrictions in the
discharge line. The discharge line
must allow complete drainage of the
valve and line. Manually operate the
relief valve at least once a year.
Also, care must be exercised
when choosing the location of
this appliance, where leakage
from the relief valve, leakage
from related piping, or leakage
from the tank or connections,
will not result in damage to the
surrounding areas, or to the lower
floors of the building. A water
heating appliance should always be
located in an area with a floor drain
or installed in a drain pan suitable
for water heating appliances. Under
no circumstances, 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
DATEREV. NAME CHANGES
REVISION
LOCATION:
Document created with version :
CONTRACT N° :
SCHEME
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L1 Main Panel
Main Power Terminal Strip
1
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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
03
CR1
12
11 14
42
41 44
03
CR2
12
11 14
42
41 44
CR2
A1
A2
X4
1 2 3
~
M
P1
Motor
Pump
04-3
04-3
04-5
04-6
04-7
04-5
04-5
X5
1
2
3
SGV1
SGV2
1
2
3
1
2
3
599 Only
12
11
14
03
42
41
44
03
12
11
14
03
42
41
44
03
04-11
04-7
18White
18White
18Black
18Black
18Red
18Black
18Green
18Red
18Black
18Green
18Black
18Red
18Black
18Black
18Black
18Red
18Red
18Green
18White
18Red
18Black
F1
SERVICE
RESET
LO
TEMPERATURE
CH
OFF
ON
-+
INNOVATIVECONDENSING TECHNOLOGY
By Hamilton Engineering, Inc.
WARNING!
#1 Turn off power
to unit
#2 Remove bottom
screw(s)
WARNING!
Before removing screw and opening front cover,
main power supply must be disconnected (shut off).
HIGH VOLTAGE - RISK OF ELECTRICAL SHOCK!
14 15 16
L L
230 VAC
Power supply
ST-7
Fuse
To Ground
OFFOFF
OFF
Service Switch
ON
INNOVATIVECONDENSING TECHNO
LOGY
ByHamilton Engineer
ing,Inc.
With HOT Controls by Hamilton Engineering Co., Inc.
#2 REMOVE BOTTOM SCREWS
Condensation Removal: This is a
condensing, high eciency appliance,
therefore condensation removal must be
addressed to avoid damage to surrounding
area or appliance. See Part 4, Section F for
Condensate Requirements (pg.26).
NOTICE
The EVO is certified as an indoor appliance.
Do not install the EVO Plus outdoors or
location where it will be exposed to freezing
temperatures. This includes all related
piping and components. If the EVO Plus is
subjected to flood water or submersed in
water, the EVO Plus must be replaced.
WARNING
Do not, under any circumstances, thread a
cap or plug into the relief valve! Explosion,
severe personal injury, death, or major
property damage may result.
WARNING

10 PART 2. ELECTRICAL
PART 2. ELECTRICAL
A. ELECTRICAL CONNECTION / REQUIREMENTS
B. INTERNAL WIRING CONNECTION
The electrical connection for the
EVO is on the bottom of the unit.
There is a 1/2” knockout location
for an electrical connection for
the heater’s incoming power
connection. All electrical wiring
must be performed by a qualified
licensed electrician in accordance
with National Electrical Code ANSI/
NFPA and/or the Canadian Electrical
Code, Part 1 CSA C22.1, or to any
applicable local codes and standards.
For your convenience, all the points
for electrical connections needed to
operate the EVO are labeled.
NOTE: Always check electrical
ground to known earth ground;
if less than 0.5 ohms, ground is
sucient (meter MUST be on
lowest setting).
We recommend a simplified test,
diering from one looking for
building earth ground issues, it is our
intent to use this test as an indicator
of equipment room (boiler or water
heater) electrical grounding issues, or
equipment bonding issues, not prove
the earth ground to the building.
Take an Ohm meter and place one
lead on a known earth ground (not
the ground wire on the boiler), and
place the other lead on either 1) The
near boiler system piping, 2) The
boiler heat exchanger, or 3) The
boiler cabinet.
If any of those readings exceed 0.5
Ohms, then it is a good indicator
that there may be sucient stray
current flowing through the water
in the piping system to accelerate
or amplify conditions that can cause
pump, boiler or piping issues in the
not too distant future.
If any readings are over 0.5 ohms,
an electrician should be brought 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 electronics for
50 Hz or 60 Hz. At every power up,
the electronics will take a couple of
seconds to compare the pulses of the
power to the pulses of the crystal,
which is built into the electronics.
Then all time-related functions are
correct no matter the power source.
The standard supplied pumps are
all 208–240 VAC, 60 cycle and are
to be wired to terminals indicated
on the appliance. In 50 cycle
applications, other pumps may need
to be supplied, depending on water
conditions.
The incoming power shall be connected
directly to the labeled, intended
connection points only. Failure to do so
may result in an electrical short and the
control board will have to be replaced!
CAUTION
It is extremely important that this unit be
properly grounded! It is very important
that the building ground is inspected by
a qualified electrician prior to making this
connection!
DANGER
Failure to confirm proper grounding and the absence of stray voltage may
result in premature component failure. See start up and commissioning
documents (LIT91111–Start Up Checklist) for details.
Terminal G (see Appendix) in the electrical compartment must be connected to
the building ground system.
The incoming 208–240 volt split phase power supply is connected to
terminals L1, L2 and N (see Appendix).
It is important that the electrical power is not turned on at this time. Double
check all connections and then turn the power on. The display that is provided
with the EVO should now be reading the Setpoint temperature.
NOTE: See Start-Up Procedures (Part 6, page 36) to change the
temperature setting or run the appliance.

DATEREV. NAME CHANGES
REVISION
LOCATION:
Document created with version :
CONTRACT N° :
SCHEME
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BCB Layout
1
2016.0.0.114
User data 2
1
0
Brian
Brian
11/15/2017
10/10/2017
Updated wire colors & AWG
X2
1
1
X21 X7
1
1
1
X13 X4
X5X22
SG E-Stop
Safety
Add
Sensor
Tank
(B) Out
1
1
X3
X15
1
X17
11
X9
11
X16X25
1
1
X8 X26 X12
1
1
X6 X10
(B) In (A) In
Therm
Room
Demand
HeatFault
(+)
0-10 Vdc
(-)
Sensor
Outdoor
Sensor
External
Cascade
(A) Out
High Limit & Outlet Sensor Gas Pressure Transducer Flue Sensor Return Sensor
Fan Pressure Transducer
Outlet Pressure Transducer Blocked Drain Transducer
Inlet Pressure Transducer
SW1
L N3
Ignition Transformer
03-11
03-12
03-13
03-14
03-3
03-2 03-3
Optional
3-Way Valve
J15
CN12
Fan
Optional
PWM Pump
03-2
BDB
+-
B/OT A/OT
04-4
04-13
04-4
04-13
04-4
04-13
04-4 04-13
04-6
04-12
04-6
04-12
04-6
04-12
04-6
04-12
Rear Wall Limit SwitchDoor Limit Switch
LWCO
Optional
See LWCO Wire
Diagram For Details
04-4 04-13
18Yellow
18
Yellow
22Black
22Brown
22Black
18Red 18Red
18Red
22Blue
22Blue
22Brown
22White
18Red
22Green
22Red
22Black
18Black
18White
18Black
18White
18White
18Black
18Black
18White
18Black | White
18Black
18White
18Gr een
22Red
22Green
18Black
22Black
22Green
22Red
22Green
22Black
22Red
18Green
22Blue
22Red
22Black
22Re d | Black 22Re d | Black 22Yellow | Black 22Yellow | Black 22Violet 22Violet 18Yellow 18Yellow 18Yellow 18Yellow
18Black 18Blue | White 18Blue | White 22Grey 22Grey
22Orange
22Oran ge
22Green
22Black
22Red
22White
22Red
18Red
03-3
11
PART 2. ELECTRICAL
B. INTERNAL WIRING CONNECTION (continued)
FIGURE 21 .2 FIELD WIRING CONNECTIONS
A. Outdoor Sensor — outdoor air
sensor, set point will adjust
based on outdoor air temperature
(not needed if 0-10 VDC output is
connected)
B. External Sensor Connection —
system temperature sensor,
senses water temp in a heating
loop.
C. Tank Sensor — Sensor for indirect
or direct DHW. An aquastat may
also be connected here.
D. 0–10 VDC — connect a 0–10
VDC output here to vary set point
temperature.
E. Additional Heat Demand —
dry contacts that will close a
thermostat on an extra heater/
boiler if the boiler is at 100% of
capacity.
F. Fault Service — alarm bell or light
may be connected here to indicate
that the boiler is a hard lockout.
G. Room Thermostat — normally
jumped. A room thermostat may
be connected here to enable/
disable the heater/boiler.
H. Cascade Connection —
communication cables get
connected here and “daisy
chained” to all heaters/boilers in a
cascade. This is polarity sensitive.
I. 3-Way Diverter Valve — Used
in a boiler system with both
Heating and Indirect Hot Water.
J. P2 — Pump for indirect. Used in
a boiler system with both
Heating and Indirect Hot Water.
K. P1 — Wire to primary pump for
boilers and heaters.
L. P3 — Wire to system pump
for boilers.

FIGURE 31 EVO
GAS CONNECTION
1/2"=1'
Dwg. By:
34000 Autry
Livonia, MI 48150
PH: [phone]
Fax: [phone] Description:
Date: Scale:
Customer:
HAMILTON
ENGINEERING
Dwg.
No.:
Checked.
By:
(2) HWD299's to HET 120
Gas
Supply
Drip
Leg
Gas
Shut-off
Valve
12 PART 3. GAS CONNECTION
PART 3. GAS CONNECTION
A. GAS CONNECTION AND INSPECTION
FAILURE TO FOLLOW ALL PRECAUTIONS
COULD RESULT IN FIRE, EXPLOSION OR
DEATH!
DANGER
The gas supply shall have a
maximum inlet pressure of less than
14” water column (1/2 PSI) (3.44
kPa), and a minimum of 4” water
column. The entire piping system,
gas meter and regulator must be
sized properly to prevent pressure
drop greater than 1” as stated in
the National Fuel Gas Code. This
information is listed on the rating
plate. It is very important that you
are connected to the type of gas
as noted on the rating plate, “LP”
for liquefied petroleum, propane
gas or “Nat” for natural or city
gas. All gas connections must be
approved by the local gas supplier,
or utility in addition to the governing
authority, prior to turning the gas
supply on. It is mandatory that a
drip leg be fabricated, as per the
National Fuel Gas code. Once all the
inspections have been performed,
the piping must be leak tested. It is
recommended that a soapy solution
be used to detect leaks. Bubbles
will appear on the pipe to indicate
a leak is present. If the leak test
requirement is a higher test pressure
than the maximum inlet pressure,
you must isolate the EVO from the
gas line. In order to do this, you must
shut the gas o using factory and
field-installed gas cocks (following
the lighting 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
greater than 14” water column, the
gas valve must be replaced.
Never use an open flame
(match, lighter, etc.) to check gas
connections.
B. GAS PIPING
The gas piping must be sized for the
proper flow and length of pipe, to
avoid pressure drop. Both the gas
meter and the gas regulator must
be properly sized for the total gas
load. If you experience a pressure
drop greater than 1” WC, the meter,
regulator or gas line is undersized
or in need of service. You can attach
a manometer to port 3 of the gas
valve (see Figures 3-2 and 3-3 on
the following page). Alternatively,
you can attach the manometer
to the incoming gas drip leg, by
removing the cap and installing the
manometer. The gas pressure must
remain between 4” and 14” during
stand-by (static) mode and while
in operating (dynamic) mode. If an
in-line regulator is used, it must be
a minimum of 10 equivalent feet
from the EVO. It is very important
that the gas line is properly purged
by the gas supplier or utility.
Failure to properly purge the lines
or improper line sizing, will result
in ignition failure. This problem is
especially noticeable in NEW LP
installations and also in empty tank
situations. This can also occur when
a utility company shuts o service
to an area to provide maintenance to
their lines. This gas valve must not
be replaced with a conventional gas
valve under any circumstances. As
an additional safety feature, this gas
valve is easily de-coupled from the
fan inlet.
Refer to the following tables to
size the supply piping to minimize
pressure drop between meter or
regulator and unit.

13
PART 3. GAS CONNECTION
C. GAS TABLES
(Based on 0.60 specific gravity for natural gas at 0.5" WC pressure drop; DOE standard is 1100 BTU per cubic foot of natural gas.)
1 Run the gas supply line in accordance with all applicable codes.
2. Locate and install manual shut o valves in accordance with state and local requirements.
TABLE 32 PROPANE SUPPLY PIPING BASED ON 11" WC SUPPLY PRESSURE
Size (in) Inches 10 20 30 40 50 60 70 80 90 100 125 150 200
BTUs
per HR
x 1,000
3/4 0.824 363 249 200 171 152 138 127 118 111 104 93 84 72 }
11.049 684 470 377 323 286 259 239 222 208 197 174 158 135 }
1-1/4 1.380 1,404 965 775 663 588 532 490 456 428 404 358 324 278 }
1-1/2 1.610 2,103 1,445 1,161 993 880 798 734 683 641 605 536 486 419 }
22.067 4,050 2,784 2,235 1,913 1,696 1,536 1,413 1,315 1,234 1,165 1,033 936 801 }
Nominal
Iron Pipe
Internal
Diameter
Length in Pipe (feet)
TABLE 31 NATURAL GAS SUPPLY PIPING
D. GAS VALVE SETUP
Models 119–399 Model 599
2
1
3
2
1
3
4
(DO NOT TOUCH LEFT
DO NOT ADJUST
increase
increase
HAND GAS VALVE!)
FIGURE 32
EVO MODELS 299399
FIGURE 33
EVO MODEL 599

Gas Pressure
Test Point
Gas Pressure
Test Point
Gas Pressure
Test Point
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
critical to the operation of any high
eciency appliance. There are three
types of measurements that must be
taken to provide the data to insure
product performance:
• Lock-up pressure (pressure in gas
piping at appliance inlet with no
load) may not exceed 14” wc. at
any time!
• 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 where to measure:
• All gas pressure tests must be
taken at the gas manifold inlet,
external to the EVO (see diagram).
• Gas pressure for minimum load
should be measured the moment
after the gas valve opens on a
single EVO, and recorded.
• Gas pressure for maximum
load shall be measured with all
units on at full fire and all other
connected loads on that gas
supply running
• Gas pressure drop shall not
exceed 1” wc. between minimum
load and maximum load as
described above.
FIGURE 34 GAS PRESSURE TESTING POINTS

15
PART 3. GAS CONNECTION
Natural Gas CO2Natural Gas CO ppm LP Gas CO2LP 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% 8.3% Less than 10 9.6% 9.4% Less than 15
HIGH FIRE 8.8% 8.6% Less than 110 10.0% 9.8% Less than 120
PLEASE NOTE: All adjustments must be made with the appliance door o, which will lower the CO2
reading 0.2%. See tables above for specific readings.
When checking or replacing a gas valve, the CO2percentage in the flue gas is the preferred measuring method to
insure proper combustion and firing rate. CO is used as the (temporary) alternate.
Changing incoming air temperature may vary the CO2setting slightly (~0.2–0.6%) after initial set up. This is not
cause for concern or reason to set up again. After one year of operation, set up is required again.
If your appliance will be operated in an area that has inlet air temperature variations greater than 80°F, please use
the following table in adjusting your CO2for optimum performance.
TABLE 33 COMBUSTION & FUEL RELATED ADJUSTMENT TABLE
Inlet air ∆T variation
Setup at minimum incoming
air temperature
Setup at maximum incoming
air temperature
80°F Reduce CO20.2% Increase CO20.2%
100°F Reduce CO20.3% Increase CO20.3%
120°F Reduce CO20.4% Increase CO20.4%
TABLE 34 CO2ADJUSTMENT TABLE
E. SETTING THE MAXIMUM LOAD
A means of sampling the leaving flue
gas is built into the vent connector
on top of the appliance. Remove the
rubber plug for testing and replace
when testing is completed. This plug
MUST be in place during normal
operation.
Enter the service function from
the setup menu. After the service
function is active, fan speed
percentage can be set. This should
be set to 100% to achieve maximum
fan speed for high fire combustion
setting.
If necessary, turn the adjusting
slot [1], which sets the high
fire performance, either
counterclockwise to increase the
CO2 percentage or clockwise to
reduce the CO2 percentage, as
shown in Figures 3-2 and 3-3,
page 11. Appropriate CO2
percentages are shown in
Table 3-3 above.

16 PART 3. GAS CONNECTION
HW 299
Fan Type Maximum RPM Minimum RPM
EBM 6300 1575
Ametek 6500 1625
HW 399
Fan Type Maximum RPM Minimum RPM
EBM 6200 1798
Ametek 7200 1800
HW 599
Fan Type Maximum RPM Minimum RPM
EBM 5800 1624
Ametek 9500 2565
TABLE 35 FAN SPEED REQUIREMENTS
F. SETTING THE MINIMUM LOAD
Set the minimum load once the
maximum load has been set, set the
fan speed in the service function to
the minimum RPM setting. In order
to set or adjust the minimum load,
turn the screw [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 valve at the right side; the left
gas valve is set by the manufacturer.
See Section H, page 17 for special
instructions on replacing both gas
valves in a model 599.
• If the measuring process takes
more than 40 minutes, the
appliance will return to the
automatic mode. If so required,
enter the Service function
another time.
• When you are done setting the
valve, press stop in the Service
function to return to normal run
mode
Please do not forget to replace the
protective cap on the gas valve!

17
PART 3. GAS CONNECTION
G. GAS CONVERSION
If the appliance is to be converted in
the field for using Propane (LPG), the
following steps must be taken:
• Turn screw [1] clockwise (Figure
3-2, page 15) ¾ of one turn (270°)
on models 299 and 1 full turn
(360°) on model HW399
• On model HW599 (Figure 3-3,
page 15) turn screw on left hand
valve closed (clockwise) and
turn right valve 1-¾ of a full turn
clockwise.
• Run the appliance. If the burner
does not ignite after four starting
eorts, turn the screw [1] one
half turn back (180°) (counter
clockwise).
• After conversion, follow the steps
in Sections E and F for setting the
maximum and minimum loads,
using the LP gas values shown in
Table 3-3, page 17.
H. GAS VALVE MAINTENANCE/REPLACEMENT
1) When checking or replacing a
gas valve, the CO2 percentage
in the flue gas is the preferred
measuring method to insure
proper combustion and firing rate.
CO is used as the alternate.
2) Gas valve replacement for the
HW 599:
The left hand gas valve (which is
normally factory-set and sealed and
must not be adjusted) must be set
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 adjustment screw [1] (see
Figure 3-3, page 15) normally used
for setting maximum flow rate must
be turned counterclockwise until
it begins to click when turned. The
screw will not fall out, but will be fully
retracted at this point. This is for
Natural Gas, for LP gas, close the
left hand valve (clockwise) until it
is closed down.
The digital manometer must now
be connected to the outlet pressure
tapping [4] on the left hand valve
only (marked do not adjust in Figure
3-3 page 15), and the appliance
fired. It must be placed in the service
mode and held at the minimum firing
rate (1653 rpm fan speed). With the
appliance firing at this rate, adjust
the oset (minimum firing rate)
screw [2] to a pressure of “0” +/-
.0.01" WC. Be sure the manometer
has been zeroed out prior to
making this setting.
Once this operation is complete,
you may follow the instructions for
setting the minimum and maximum
firing rate as shown in Sections E
and F, for the right hand gas valve
only.
FAILURE TO FOLLOW ALL PRECAUTIONS
COULD RESULT IN FIRE, EXPLOSION OR
DEATH!
WARNING

18 PART 4. VENTING
PART 4. VENTING
A. APPROVED VENTING MATERIALS
ALL VENT PIPE MATERIALS AND FITTINGS MUST COMPLY WITH THE FOLLOWING:
Item Material Standards for installation in:
United States Canada
Vent pipe
and
fittings
AL 29-4C Stainless ANSI/ASTM UL1738 UL1738
PVC schedule 40* ANSI/ASTM D1785 CPVC and PVC venting must be ULC-S636
Certified. IPEX is an approved vent
manufacturer in Canada supplying vent
material listed to ULC-S636.
CPVC schedule 40 ANSI/ASTM F441
Polypropylene ULC-S636 ULC-S636
Pipe cement
& primer
PVC ANSI/ASTM D2564 IPEX System 636
Cements & Primers
CPVC ANSI/ASTM F493
NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE
Please note: Venting system may contain one or more of the above materials.
The EVO is a direct vent appliance. The EVO is listed as a Category IV condensing appliance. (The EVO
Venting is rated at Zero Clearance to combustibles.)
THE EVO EFFICIENCY 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 REQUIRED FOR YOUR INSTALLATION.
SPECIAL VENTING SYSTEM DESIGN NOTES
It is extremely important to follow these
venting instructions carefully. Failure to do
so can cause severe personal injury, death
or substantial property damage.
This vent system will operate with a positive
pressure in the vent pipe. Do not connect
vent connectors serving appliances by
natural draft into any portion of mechanical
draft systems operating under pressure.
DANGER WARNING
NOTE: For concrete construction or to meet certain fire codes, exhaust and inlet piping at the wall penetration to the
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.

19
PART 4. VENTING
B. VENTING THE EVO
TABLE 41 VENTING SPECIFICATIONS
Model
Vent
Diameter Standard Vent Type Optional Vent Type
Minimum Combined Vent
Length
Maximum Combined
Length
HW 299 4" Plastic Stainless 6' + (2) 90º elbows 225'
HW 399 4" Plastic Stainless 6' + (2) 90º elbows 180'
HW 599 5" 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 5'
45 degree elbow 3'
Coupling 0
Air inlet elbow 6'
Exhaust coupling 1'
The inlet and exhaust pipes on the top of 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 fittings. Inlet pipe size must not be reduced. Do not combine the inlet air or exhaust with any other inlet or
exhaust pipe including either to an additional similar appliance, unless you have purchased an engineered Common
Venting System from Hamilton Engineering, Inc. The joints must be properly cleaned, primed and cemented if plastic,
and sealed per the manufacturer’s instructions if stainless. The piping must also be properly supported as per Local
and National Standard Plumbing Codes. It is important that the piping must be clean and free from burrs, debris,
ragged ends and particles of PVC (if applicable).

20 PART 4. VENTING
1) Never vent into a walkway, patio area, alley or otherwise public area less than 7' from the ground. (See detail
below references Fig. A.12.9 in the National Fuel Gas Code 2009 “Exit Terminals of Mechanical Draft and Direct-
Venting Systems;” see Figure 4-1, pg.21)
2) Never vent over or under a window or a doorway where the exhaust plume or condensation liquid will cause
obtrusive or dangerous conditions. (Refer to National Fuel Gas Code, CAN B149).
3) Never install a heat saver or similar product to capture waste heat from exhaust.
4) Always have a vent location at least 12" above maximum snow level.
5) Always have vent a minimum of 24" above ground level, away from shrubs and bushes.
6) Follow local gas codes in your region or refer to National Fuel Gas Code, Can B149.
7) Always have at least 36" distance from an inside corner of the outside walls.
8) Maintain at least 48" clearance to electric, gas meters, windows, exhaust fans, chimneys, inlets or mechanical vents.
9) VERY IMPORTANT! The inlet air connection must be connected to outside air and should be located no closer
than 8" and no further than 24" to the exhaust.
10) Always place screens in all openings in intake and exhaust to prevent foreign matter from entering the EVO.
11) The vent intake 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 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.).
B. VENTING THE EVO (continued)
The following are code restrictions for the location of the flue gas vent terminal.
Compliance to these requirements doesn’t insure a satisfactory installation; good common
sense must also be applied. It is important to make sure that exhaust gases are not
recirculated into the inlet air of the EVO. If there is any doubt, contact the factory BEFORE
installing.
NOTICE
Exhaust piping should be sloped
back to the connection on the EVO,
at least 1/4” per foot to remove
additional condensate that forms
within the pipe. The total combined
length of pipe (intake piping plus
exhaust piping added together)
including elbow allowances intake
and exhaust should not exceed the
length shown in the vent table. The
minimum combined vent length
should not be less than a combined
length of 6’ plus two 90° elbows.
Choose your vent termination
locations carefully. You must also
make certain that exhaust gas does
not re-circulate back into the intake
pipe. You must place them in an
open area and follow the following
guidelines: