INNOVATIVE CONDENSIN TECHNOOY By Hamilton Engineering, Inc. ADDENDUM TO IT91127U EVO 79-599 CONFIURED IN ODD WATER SYSTEM DESIN WARNIN 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.
All safety precautions referenced to in IT91127U (EVO 79-599 Universal Installation and Operating Manual) should be STRICTY adhered to! There are two basic system configurations. lease determine which style you have and refer to the specific instructions where indicated. lease contact Hamilton Engineering, Inc. at 800.968.5530 if you have any questions regarding system configurations. (FIURE 1) SYSTEM DESIN A This system design employs a storage tank with integral heating coils and will require only one circulating pump. (FIURE 2) SYSTEM DESIN B This system design employs an external heat exchanger and requires one circulating pump for the closed loop (boiler) side and a bronze pump for the fresh water (storage tank) side. age 2 of 9
SYSTEM REQUIREMENTS System requirements beyond what is listed here can be found in IT91127U (EVO 79-599 Universal Installation and Operating Manual): Electrical: System B: 208 240 volt amperage per system rating plate, 208-230 volt per stainless steel pump rating plate. Wiring diagram is located on page 9 of this Manual. Service Clearances: System B: rovide adequate access to heat exchanger for periodic acid cleaning and or removal for additional service as required System operation: System A The 4006A storage tank temperature control shall be set at the desired storage tank water temperature (per original design), on approximately a 5 F drop from desired setpoint, the SST switch in the 4006A will make, closing the heat enable circuit on the heating boiler. After receiving this signal, the boiler control will start the cast iron pump and initiate a firing sequence and provide the required closed loop water temperature (generally 150 F 180 F; see system design specifications) as set by user on the red wheel located next to the temperature display on the front of the boiler, to provide the designed recovery rate through the tank heat exchanger. If there is more than one boiler providing the required BTU capacity, the setting and control wiring shall be done on the ead labeled boiler only. System B - The 4006 storage tank temperature control shall be set at the desired storage tank water temperature (per original design), on approximately a 5 F drop from setpoint, the control will close both internal SST switches, simultaneously starting the bronze circulating pump and closing the heat enable circuit on the heating boiler. After receiving this signal, the boiler control will start the cast iron pump and initiate a firing sequence and provide the required closed loop water temperature (generally 150 F 180 F; see system design specifications) as set by user on the red wheel located next to the temperature display on the front of the boiler, to provide the designed recovery rate through the external heat exchanger. If there is more than one boiler providing the required BTU capacity, the setting and control wiring shall be done on the ead labeled boiler only. Filling Instructions: The Odd Water system comes equipped with a pressure reducing fill station for the boiler (closed loop) side of the system, that is pre-piped to EVO system city water connection. Included in this package are a low pressure switch, pressure gauge, air vent, pressure reducing fill valve, expansion tank, check valve, backflow preventer, isolation valves, optional water meter, and a union for easy disassembly. Once the city water connection is made, open the air vent in the fill package and on the top of boiler(s) (models 299-599 ONY). Once the air vent(s) is open, turn on the city water supply and open the (3) isolation valves, each located on the expansion tank, near the city water connection, and after the pressure reducing valve. When air is no longer bleeding out of the air vent(s), turn the boiler(s) on, which will cycle the pump(s), purging any air remaining in the system. NOTE: There MUST be a city water supply connected that is regulated down to 12 SI (via the RV supplied) for the system to work properly! age 3 of 9
2 3 2 1 1 3 4 4 5 6 5 (FIURE 3) SYSTEM DESIN A WITH ARTS H I J K F (Optional) A City Water Connection E (Optional) Q N B D M O (TABE 1) SYSTEM DESIN A - ARTS C A B C D E F H I J K M N O Q etter on diagram Description EVO unit Cast Boiler Side ump Condensate Neutralizer Hydronic Expansion Tank - 12 SI air charge Storage Tank 4006A Temperature Control ow ressure Switch ressure auge Air Vent Fill Valve Check Valve Water Meter (optional) Backflow reventer Hot Water Connection Drain Valves Cold Water Connection Domestic Expansion Tank (optional) age 4 of 9
SYSTEM B - ARTS (FIURE 4) SYSTEM DESIN B WITH ARTS H I J O City Water Connection K M N B A T C D R E F S (Optional) Q (TABE 2) SYSTEM DESIN B - ARTS etter on diagram A B C D E F H I J K M N O Q R S T Description EVO unit Electrical Disconnect Cast Boiler Side ump Condensate Neutralizer Hydronic Expansion Tank - 12 SI air charge Stainless Steel Domestic Hot Water ump Brazed late Heat Exchanger Air Vent ressure auge ow ressure Switch Fill Valve Check Valve Backflow reventer Water Meter (optional) Storage Tank External Heat Exchanger Cleaning and Draining orts Brass Wye Strainer Normally Closed Cleaning Bypass Valve Domestic Expansion Tank (optional) 4006 Temperature Control age 5 of 9
ADDITIONA INFORMATION Both system designs are completely factory assembled and tested prior to shipping, following assembly at the installation site, however, filling the system requires that proper practices be followed: The boiler is designed to operate in a closed-loop system. As such, the system should be tight and not require make-up water. A high percentage of untreated make-up water may cause premature failure due to buildup of scale; such failure is not covered by warranty. Scale can also reduce efficiency. For example, a scale thickness of 1/16 will result in a 12.5% loss of efficiency. NOTE: Minimum system fill pressure is 12 SI! Water ph The ph of the hydronic system fluid must be between 6.5 and 7.5, for untreated water only. A periodic check of the system ph should be conducted to ensure these ph levels are maintained. IMORTANT! lycol and other additives must be approved by the chemical manufacturer for use in 316 stainless steel boilers as well as the circulating pumps used with the boilers and heating system, and you must maintain the required ph levels as recommended by the glycol or treatment chemical manufacturer to prevent damaging the boiler and or pumps. If the water quality exceeds our known safe thresholds, we wave the red flag of caution: 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 (mg/l) H - 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). The amount of oils, fats, grease, and other organic matter should be limited to 10 ppm. Consult your water conditioning or chemical treatment supplier for analysis and recommendations. Flushing the System Before filling the boiler, flush the system to remove any debris from construction or maintenance. Clean and flush old piping thoroughly before installing the boiler. IMORTANT! Under no circumstances should the hydronic system be flushed while the boiler is attached to the system since the debris or corrosion products could accumulate in the boiler and plug the boiler heat exchanger. IMORTANT! If the piping system attached to this unit will be chemically cleaned, the boiler must be disconnected from the system and a bypass installed so that the chemical cleaning solution does not circulate through the boiler. Following chemical cleaning, the system should be thoroughly rinsed to remove cleaning agents prior to reconnecting the boiler to the system. age 6 of 9
ODD WATER WIRIN DIARAMS EAD OR SINE BOIER ONY - SYSTEMS A & B A B C D E F H I J K M ST-1 ST-2 ST-3 ST-4 ST-5 ST-6 ST-7 1 2 3 4 5 6 Outdoor Sensor External Sensor Indirect Sensor or Aquastat 7 + - 0-10 VDC 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Additional ock Out Heat Source Signal Dry Contact Dry Contact Remote Thermostat + - Cascade Connection not in use 1 2 1 open com. close Divertor Valve Indirect 2 1 ump 2-indirect 1 2 ump 1 2 ump 3 1 26 27 28 1 2 ower Supply 208-240 Vac For use with Central heating for outdoor reset Used for storage tank or common line sensing Used for indirect tank Building management system For use with additional heat needed w/cascade For use with alarm bell / light Connection from 4006 thermostat Must connect + to + and - to - between appliances in cascade Used in a boiler system with both CH & DHW ump 2: Used in a boiler system with both CH & DHW ump 1: Boiler ump ump 3: Heater ump To round Service Switch Fused switch or from a maximum 15 amp dedicated circuit breaker age 7 of 9
ODD WATER WIRIN DIARAMS EAD OR SINE BOIER ONY - SYSTEM A 240v ower Supply Tank Stat TST 63000 ressure Switch HYD 47001 EVO ower/control Terminal Strip ST-1 ST-2 ST-3 ST-4 ST-5 ST-6 ST-7 1 3 4 5 6 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 + - 1 2 1 1 2 1 2 Outdoor External Indirect + - Additional ock Out Remote Cascade open com. 0-10 close Heat Signal ump 1 Sensor Sensor Sensor Thermostat Connection Divertor Valve Indirect ower Supply VDC Source Dry 2 1 208-240 Vac or 2 1 Dry Contact Aquastat ump 2-indirect Contact ump 3 208-240 v 1 ph ower Supply SETOINT TEMERATURE RESET SERVICE - + BURNER ON 240V Boiler ump Service Disconnect HAMITON ENINEERIN Dwg. No.: 34000 Autry St. ivonia, MI 48150 H: (800) 968-5530 Fax: (734) 419-0209 Checked. By: Dwg. By: Customer: Description: Date: Scale: NTS 2 7 8 9 not in use AE 10/29/10 Control wiring diagram for Odd Water system Type A (with Indirect tank) age 8 of 9
EAD OR SINE BOIER ONY - SYSTEM B 240v ower Supply Tank Aquastat TST 54006 ressure Switch HYD 47001 EVO ower/control Terminal Strip ST-1 ST-2 ST-3 ST-4 ST-5 ST-6 ST-7 1 3 4 5 6 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 + - 1 2 1 1 2 1 2 Outdoor External Indirect + - Additional ock Out Remote Cascade open com. 0-10 close Heat Signal ump 1 Sensor Sensor Sensor Thermostat Connection Divertor Valve Indirect ower Supply VDC Source Dry 2 1 208-240 Vac or 2 1 Dry Contact Aquastat ump 2-indirect Contact ump 3 208-240 v 1 ph ower Supply SETOINT TEMERATURE RESET SERVICE - + BURNER ON 240V Boiler Side ump 240V Tank Side ump Service Disconnect HAMITON ENINEERIN Dwg. No.: 34000 Autry St. ivonia, MI 48150 H: (800) 968-5530 Fax: (734) 419-0209 Checked. By: Dwg. By: BD 06/17/09 NTS Customer: Description: Date: Scale: 2 7 8 9 not in use Boiler #2 Boiler #1 Control wiring diagram for Odd Water system Type B age 9 of 9