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Sizing, Installation November 2008

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1 Sizing, Installation November 2008
Quietside ODW 099A-199A Sizing, Installation November 2008

2 Agenda Product & Features What Size & Flow rates
What’s needed for installation Gas Pipe Sizing Hanging on the wall Water Piping Condensate piping Venting Power wiring Control Wiring Start up Checking operation Maintenance Troubleshooting

3 ODW 099A – 199A

4 Line Up 4 models in 2 Chassis sizes
099 & 120 : Smaller capacities designed for lighter demand applications – Condos, apartments, cottages, townhouses or houses where low to medium demand exists 180 & 199 : High capacity for higher demand application - larger residences or any application where “performance bathing or showering” is in place

5 Modulation Range ODW 099A : 18,000 to 99,000 Btu/h

6 Why ODW? Efficiency, Energy Factors above 0.9 (Energy Star approved
Condensing water heater, Flue Gas temperature below 136DegF allows venting in Schedule 40 PVC Stable Delivered Water Temperatures Rebates!!!!!!

7 Delivered Water Temperature Control
A stable delivered water temperature is of paramount importance We have 3 temperature sensors on this unit Entering Cold Water temperature Water temperature exiting the Heat Exchangers Delivered Water temperature

8 Delivered Water Temperature Control
2 Control valves are used Flow Control Valve Measure the flow rate through the unit and report back to the main controller Minimum flow rate for operation is 0.7 GPM

9 Delivered Water Temperature Control
Bypass Control Valve This valve allows water to flow from supply to delivered water without passing through the heat exchanger

10 Why Bypass Control? Mixing in some cold water allows for a stable delivered water temperature, no peaks and troughs due to burner modulation Increases flow rate as we can provide a mixed condition water temperature Provides flow control in times of extremely high flow rates

11 End Result Exactemp Reduced temperature fluctuations compared to competition and previous iterations of Tankless Water heaters

12 Sizing your ODW

13 Sizing is simple Sizing takes into account the number of fixtures and type of hot water uses in the house, plus the number of occupants How many, what is the expected flow rate through them, and how many could/will be used simultaneously Total this and this is your max flow, then……

14 Sizing – Bathing Typical Shower is 2.5 GPM, 1.5 GPM for Lo Flo Heads
Body Sprays : 2 to 2.5 GPM Roman or Whirlpool Tubs : 4 to 8 GPM Will any showers or tubs will be running at the same time?

15 Sizing – Other Uses Faucet is 0.75 GPM Dishwasher, 1.5 GPM
Washing Machine, 2 GPM Will we use Dishwasher, Washing Machine simultaneously with showers etc

16 Sizing Once we have the number of hot water uses, plus how the lifestyle of the household affects hot water usage we can calculate a maximum flow rate This number is then used for the second step Example of sizing 2 people household – 2 baths Bath 1 : Shower Head – standard flow, Hand Held, Body Sprays Bath 2 : Shower Head – standard flow 4 Faucets Washing Machine Dishwasher

17 What’s the groundwater temp?
Q : Why is that important? A : For a fixed delivered water temperature the max flow rate available for a given Btu/h varies based on the difference in temperature between the cold water and the required set point This is called ∆T and is one of the most important items to know when sizing an ODW unit


19 Delivered Domestic Hot Water Temp (DegF)
Performance ODW-099A Delivered Domestic Hot Water Temp (DegF) GPM 100 105 110 120 130 140 Min. Max. Cold 35 0.5 2.74 0.46 2.54 0.43 2.37 0.38 2.09 0.34 1.87 0.31 1.69 Water 40 0.54 2.97 0.4 2.22 0.36 1.98 0.32 1.78 Temp 45 0.59 3.24 DegF 50 0.65 3.56 55 0.72 3.95 60 0.81 4.45 65 0.92 5.08

20 Delivered Domestic Hot Water Temp (DegF)
Performance – ODW 120A Delivered Domestic Hot Water Temp (DegF) GPM 100 105 110 120 130 140 Min. Max. Cold 35 0.5 3.32 0.46 3.08 0.43 2.88 0.38 2.54 0.34 2.27 0.31 2.05 Water 40 0.54 3.59 0.4 2.7 0.36 2.4 0.32 2.16 Temp 45 0.59 3.92 DegF 50 0.65 4.31 55 0.72 4.79 60 0.81 5.39 65 0.92 6.16

21 Delivered Domestic Hot Water Temp (DegF)
Performance – ODW 180A Delivered Domestic Hot Water Temp (DegF) GPM 100 105 110 120 130 140 Min. Max. Cold 35 0.72 4.98 0.67 4.62 0.62 4.31 0.55 3.81 0.49 3.41 0.45 3.08 Water 40 0.78 5.39 0.58 4.04 0.52 3.59 0.47 3.24 Temp 45 0.85 5.88 DegF 50 0.93 6.47 55 1.04 7.19 60 1.17 8.09 65 1.34 9.24

22 Delivered Domestic Hot Water Temp (DegF)
Performance – ODW 199A Delivered Domestic Hot Water Temp (DegF) GPM 100 105 110 120 130 140 Min. Max. Cold 35 0.72 5.5 0.67 5.11 0.62 4.77 0.55 4.21 0.49 3.77 0.45 3.41 Water 40 0.78 5.96 5.50 0.58 4.47 0.52 3.97 0.47 3.58 Temp 45 0.85 6.50 DegF 50 0.93 7.15 55 1.04 7.95 60 1.17 8.94 65 1.34 10.22

23 Don’t just select the largest unit
Even though it is tempting don’t just select the largest unit available Unit modulation may cause it to cycle at combinations of very warm incoming water and low water flow rates Also we need to make sure that the gas supply piping is correctly sized

24 Water Requirements Water Quality
These are the maximum values of the minerals in the water Having higher levels of these minerals can cause furring of the Heat Exchangers plus reduced efficiency

25 Water Requirements What to do about Water Quality
Service the unit (frequency dependant on water quality) Or Treat the water before it enters the water Several different methods available over the counter

26 What do you get included?
Unit, set up for Natural Gas operation Unit Controller Vent Termination kit, including co-axial flue, termination kit Isolation kit, includes Ball Valves, purge valves and ASME rated Pressure Relief Valve

27 What do you supply? Gas piping, minimum ¾” but selected for the Btu/h input capacity of the unit Schedule 40 PVC venting including Elbow and Bird Screen for vent Water piping from cold supply to unit and hot water piping to house 115V power, power wiring and thermostat wire to the controller(s)

28 Installation basics Indoor location only – the unit doesn’t like getting wet Minimum ambient temperature above 45 DegF, even with the freeze protection heaters Respect the necessary clearances to the front, sides, back, top and bottom of the unit

29 Gas Piping - Basics Natural Gas Pressure - Primary 3.5” to 10.5” WC
LP Gas Pressure - Primary 8” to 13” WC Gas meter must be capable of supplying total gas demand for the residence Gas pressures below the minimum will reduce performance Ensure gas pressure does not drop on initial start or unit may become noisy in combustion Do not use Flexible Gas Lines unless they are rated for a Minimum capacity of 250,000 Btu/h

30 Gas Piping - Basics Gas pipe size is determined by two factors
Max Input capacity of the appliance connected Distance from the Gas meter The larger the appliance and the further away from the meter the larger the gas pipe size

31 Gas Piping - Sizing Determine where the unit will be installed on the gas pipe Closer to the meter is always better If unit is located at furthest point from the meter considering running a dedicated stick of black iron directly from the meter to the ODW

32 Gas Piping - Basics

33 Gas Piping – Sizing

34 Gas Piping - Sizing

35 Gas Piping - Sizing Connection from the stick to the unit
If using flexible gas piping make sure it is capable of supplying a minimum of 250,000 Btu/h Always install a gas shut off valve and drip leg adjacent to the unit

36 Hanging the unit on the wall
Remove unit from Carton Unit installs on a hanging bracket (supplied) mounted to studs or wall brace CANNOT be installed on a combustible wall. Use non combustible backing plate e.g. Durarock or 24g sheet metal

37 Water Piping (cont) Cold Water inlet including strainer
Hot Water outlet

38 Water Piping 2 Connections – Cold In, Hot Out
¾” Isolation Valve package included with the unit Ball Valves, Purge Valves, 150 Psi Pressure Relief Valve ¾” threaded connection ODW 099/120 includes a ½” adaptor from the isolation valve kit – but ¾” connection to the house

39 Water Piping (cont) Isolation Valve kit includes a Pressure Relief Valve to meet code requirements, rated at 150 psi Pipe PR Valve to building drain or other suitable area A Temperature Relief Valve is not required unless local codes mandate it – however if one is installed do not install with the probe directly in the water flow

40 Water Piping (cont) Unit is designed for Potable water only, therefore all piping should be suitable – Copper, PEX (where allowed by code), etc If the unit is providing potable hot water, it cannot be connected by code to a heating system using non-potable components or chemicals Make sure cold water feed pressure is above 14 Psi and below 125 Psi – if outside that range installing a pump or de-pressurizing pump


42 I want “Instant” Hot Water!
Recirculation – Based on time or temperature Pump sized to push water through the unit to remove the cold plug contained in the lines Taco Dmand system Unit takes 3 seconds to go from sensing flow to firing. This is a big advantage over other Tankless Water Heaters, reduces cold water sandwiching


44 Condensate Piping Unlike other Tankless water heaters the ODW is a condensing model Therefore it will produce condensate which has to be drained away The condensate siphon inside the unit must be filled prior operating – Without filling flue gases can enter the home

45 Useful advantages of condensing
Lower Flue gas temperatures ODW maximum flue gas temperature is 136 DegF This allows venting in Schedule 40 PVC in all states and provinces, with zero clearance This is a big advantage over other Tankless Water Heaters, required to be vent in single wall stainless steel (which is not B vent)

46 Venting Description – Sealed combustion or Direct Vent
Both Intake and Exhaust air must be provided to the unit Ø3” for 099 & 120 Ø4” for 180 & 199

47 Venting Maximum vent length is 45ft equivalent, this is a per pipe length not a total Maximum 3 Elbows in vent pipe Each Elbow = 5ft of straight pipe, therefore with 3 Elbows in the system the maximum length of straight pipe is 30ft

48 Vent Connection on unit
Plastic connection to accept either 3” or 4” vent pipe directly on top of the unit Approved PVC cement is required to bond the two together Use Hi Temp Silicone seal on the joint to ensure a full seal


50 Vent Piping Always slope flue pipe back to the unit – 1” in 12” minimum This allows any condensate produced in the flue pipe to return to the unit and drain through the condensate system Prevents growth of ice stalactites on the outside of the building penetrations through the building required Zero Clearance to combustibles

51 Termination Location Vent Termination must be located
Minimum of 12” above grade OR 12” above anticipated snowfall level 10” below eaves or building overhang 12” from windows, openings and other venting 24” clearance in front of the termination Away from plants, trees, animals

52 Wall Penetration Two penetrations through the building required
Z Dimension ODW is 4 ½” Z Dimension ODW is 6”

53 Flue Termination Flue termination included – Stainless Steel
Attach to the Flue pipe with the connection provided Seal around PVC joint and termination with hi temperature Silicone Seal

54 Termination Cover Once Flue termination is connected attach the Termination cover to the building Slide over the flue and Intake pipes (larger opening is for the air intake) Screw to wall with 4 screws – provided Seal around flue termination with high temperature Silicone

55 Inlet Air 90 Deg Elbow plus birdscreen – Supplied by installing contractor Attach to the Flue pipe use PVC adhesive Must be located with inlet facing downwards to prevent rain/snow/debris entering the unit

56 Other than Sidewall Unit can be vented
Flue and Intake Air from separate barometric planes i.e – Flue gas vented through one wall, with Intake supplied via a penetration on a different wall

57 Vertical 2 x 45 Deg angles on the flue are mandatory
Prevents any pooling of condensate in the flue pipe 2 x 90 Deg Elbows required on the Intake pipe Note clearances – if in areas of snowfall ensure air intake is 12” above anticipated snowfall accumulation

58 Power Wiring Unit is powered from a 115V, 15A dedicated and grounded power supply Unit has 2 x 3 Amp glass style fuses to prevent damage occurring to the microprocessor or other components dues to power issues Wire power to unit per local codes regarding connection to the wiring of the unit Currently this will possibly include adding a junction box adjacent to the unit, depending on local codes

59 Unit Control Standard control is via a wired controller which can be mounted either adjacent to the water heater or in a bathroom An optional Priority controller is available for a total of 2 controls on the system

60 Controller Up and Down Buttons set the required hot water
temperature from the unit Temperature can be set from DegF in 2 DegF increments or 120, 130, 140, 150 & 160 DegF settings Factory default is 104 On/Off Button turns the Unit On or Off as required Priority button allows the second thermostat to override the main

61 Optional Priority Controller
Priority Light is lit. This allows the Second thermostat to override the main Use if you want a hotter shower than allowed for a kid’s shower Up and Down Buttons set the required hot water temperature from the unit different to that of the main controller Temperature can be set from DegF in 2 DegF increments or 120, 130, 140, 150 & 160 DegF settings Factory default is 104 On/Off Button turns the Unit On or Off as required

62 Wiring Standard Controller
2 Wire Connection Yellow Wires Thermostat Wire No Polarity 20V DC

63 Wiring Priority Controller
2 Wire Connection Yellow Wires Thermostat Wire “Piggy Back” No Polarity 20V DC

64 Ready for Start Up? Water Piping – Flushed, Leak Free?
Gas Piping – Purged, Leak Free? Electrical/Control wiring – Ready to go? Dip Switches set – Huh?

65 Dip Switches? Dip 1 : LP or Natural Dip 2 : Vent length
Dip 3 : Program Dip 4 : Max Fire Dip 5 : Min Fire

66 Dip Switch Settings #1 : Fuel Type
Switch ON for conversion to LP from Natural Gas LP conversion requires replacement of burner assembly Model ODW 99 ODW 120 ODW 180 ODW 199 Burners 15 EA 20 EA Size LNG : Φ1.48 * 5EA / Φ1.38 * 10EA LPG : Φ1.12 * 5EA / Φ1.03 * 10EA LNG : Φ1.65 * 20EA LPG : Φ1.20 * 20EA

67 LP Gas Conversion Replace burner manifold assembly with one specific to LP Change dip switch #1 to ON - tell the unit that it is now LP

68 Dip Switch Settings #2 Vent Length
Switch OFF for Vent lengths less than 16ft Switch ON for Vent lengths greater than 16ft

69 Dip Switch Settings #3 Set Up Mode
Switch to ON to put the unit into set up mode, change display, check operating parameters

70 Dip Switch Settings #4 & #5 Minimum and Maximum firing rate
Locks the unit in either Minimum or Maximum firing rate

71 Unit Start Up Once the system is set up, open valves on water connections, allow unit to fill with water and flow water through the unit for 5 minutes Open Gas Valve and check for leaks Power up unit, set temperature and open up faucets to allow unit to start and produce hot water

72 Unit Start Up Unit should now start, operate unit until a steady flow of water is seen at all faucets, showing that air has been removed from the system Unit should now control to flow and set temperature If a fault code appears………….

73 Fault Codes Code Fault Description A0 Flow Control Valve (FCV) Faulty
Pseudo Flame A1 By-pass Control Valve (BCV) A9 Freeze Protection In Combustion Fan Failure AA Inlet Temp Sensor Failure A3 Communication Error Ab HX Temp Sensor Failure A4 Over Heat Ac Delivered Water Temp Sensor A5 Outlet Water Temp Ad Condensate A6 Ignition Failure AE Air Pressure Switch A7 Gas Valve Failure AF

74 Fault Codes All Fault codes with the exception of A5 are a hard lockout, meaning that the power to the unit has to be cycled to reset the system If the wired remote is broken, removing it and crossing the wires together will allow the unit to run, but with the setpoint of 104 DegF

75 A0 – Flow Control Valve Error
Flow control Valve has 2 functions, sense the flow rate and control to flow to maintain the set temperature If the flow rate demand exceeds the unit capacity the valve will throttle to maintain set temperature, rather than reducing the delivered temperature and maintain flow

76 A0 – Flow Control Valve Error
A0 will show if the micro commands the solenoid to open or close and it does not, OR If the signal from the flow sensor cannot be read by the micro Solution – check connections, replace valve

77 A1 – Bypass Valve Error Bypass Valve also has 2 functions, act as a mixing valve to provide a stable delivered temperature and also protect the HX from over condensing Thx > Td + 18~27°F

78 A1 – Bypass Valve Error A1 will show if the micro commands the valve to open or close and it does not Both valves are worm drive solenoid style similar to the EEV on a Samsung unit Solution – Check connections,

79 A2 – Combustion Fan Error
Combustion Fan is a BLDC type fed with 4 wires from the micro Fan speed varies with capacity, signal is from 5V-45V DC Fan signals back to the micro, it’s speed and rotation as part of the feedback loop

80 A2 – Combustion Fan Error
A2 fault is caused by the fan either not operating, going backwards or not sending a feedback signal to the Micro White wire is feedback, should be >100Hz with fan running Black ~ Yellow is 12V DC, if no voltage is present = faulty micro Black ~ Red is variable 5V – 45V DC, with the motor disconnected should read 45V DC, connected dependant on capacity Solution : Check for signal, check for rotation (no winds), check motor resistance, replace either fan or micro

81 A3 – Communication error
Micro and Wired remote communicate together for set point error codes etc DC voltage 20V DC A3 is shown when Micro and Controller cannot communicate Solution : Check wiring between units (not polarity sensitive), replace controller first

82 A4 – Over Heat Error Auto Reset Bi metallic Over Heat Cut Out
Opens at 203°F, closes at 176°F Normally closed, check with multi-meter Solution : check strainer, check flow through the unit, flush unit if in hard water area, replace OHC

83 A5 – Outlet Water Temp Error
Sensed by the Delivered Water Temperature sensor If the Delivered water temp exceeds 203°F the unit will shut down and display A5 Auto Reset, unit will overheat if it is really delivering 203°F water

84 A6 – Ignition Failure Unit will try to start 3 times before giving this error code Causes No Gas Faulty Gas Valve Micro problem Faulty Igniter Flame Detection

85 A6 – Ignition Failure No Gas
Remove Philips head screw check for gas pressure If none check SV1 for power (120V AC) and check gas supply Also there is a master On/Off switch in the unit controlling output to the gas valve, make sure that is ON Check gas supply outside unit, especially for LP fuelled units

86 A6 – Ignition Failure Faulty Gas Valve
Check voltage to SV1, SV2 and SV3 for 120V AC If voltage is present, check resistance of SV1, SV2, SV3 SV1 = 1650Ω SV2 = 1650Ω SV3 = 1650Ω

87 A6 – Ignition Failure Faulty Gas Valve
Check Voltage to modulating coil should be between 5V DC to 15V DC (Min fire to Max Fire) MV resistance is 77Ω If there is zero volts at the Modulating valve gas pressure should still read approx 3/8” WC if SV1 is open

88 A6 – Ignition Failure Microprocessor
No voltage being supplied to either SV1, SV2 or SV3 and the modulating valve is a microprocessor problem If there is zero volts at the Modulating valve gas pressure should still read approx 3/8” WC if SV1 is open Voltage to the Igniter, should be 120V AC

89 A6 – Ignition Failure Faulty Igniter
Check voltage to the igniter, primary voltage should be 120V AC Secondary voltage is 15kV to 18kV Check Primary/Secondary resistance to ground Primary : 1MΩ Secondary : 720Ω

90 A6 – Ignition Failure Flame Detection
Micro sends a 24V AC signal to the flame detector No Flame is a 0V signal back to the micro If a Flame is present, should read 0.3µA ~ 1.2µA to ground

91 A7 – Gas Valve Error Faulty Gas Valve Failure of SV1 or SV2 to open
Check voltage to SV1, SV2 and SV3 for 120V AC If voltage is present, check resistance of SV1, SV2 SV1 = 1650Ω SV2 = 1650Ω If voltage is not present, problem lies with the Micro Solution : Replace whichever component is faulty

92 A8 – Pseudo Flame Pseudo Flame is where the unit receives a signal from the flame detector either prior to SV1, 2 or 3 opening OR detecting a flame after the unit has shut down Either faulty flame sensor or Microprocessor, but we can check to make sure no gas is leaking through the gas valve solenoids

93 A9 – Freeze Protection Freeze Protection occurs when the cold water temperature entering the unit is below 23°F OR -5C This is to protect the unit against freezing and also against over production of condensate Unit will restart when the incoming cold water is above 32 DegF

94 AA – Inlet Temperature Sensor
Inlet temperature sensor measures the incoming cold water to the unit Very important as this helps set the capacity requirement Error occurs if the sensor is open circuit or out of range, check with multi meter for resistance 40°F = 20,000Ω 50°F = 15,500Ω 60°F = 12,600Ω

95 Ab – HX Temperature Sensor
HX temperature sensor measures the water temp leaving the heat exchangers Very important as this sets the By Pass valve opening for a stable delivered water temperature Should measure about 15-20°F higher than delivered water temperature Error occurs if the sensor is open circuit or out of range, check with multi meter for resistance 120°F = 3,400Ω 140°F = 2,500Ω 160°F = 1,800Ω

96 Ac – Delivered Water Temp Sensor
Delivered water temperature sensor measures the final delivered water temperature to the faucet This is the temperature seen by the end user Error occurs if the sensor is open circuit or out of range, check with multi meter for resistance 104°F = 4,900Ω 110°F = 4,200Ω 120°F = 3,400Ω

97 Ad – Condensate Overflow
Unit produces condensate which is collected in a siphon, if the drain is blocked the condensate can back up into the wet recuperative HX, causing issues with airflow and other components We have an electrode to sense if the siphon is full and stop the unit before this can occur Micro sends 24V AC signal to electrode which as it is above the water has a resistance of ∞ If the electrode touches the condensate resistance fall to <100Ω and the error occurs

98 AE – Air Pressure Switch
Monitors flue pressure across the unit, compared to atmospheric pressure Normally closed switch, opens on failure ODW099 & 120 opens at ½” WC ODW180 & 199 opens at 5/8” WC Control voltage 5V DC

99 AE – Air Pressure Switch
Two hoses #1 – Back of cabinet for atmospheric pressure, very important that no insulation be applied to the back or the unit and the unit is not mounted flush to the wall #2 – Fan Throat, upper port on the back of the fan Failure can be due to, blocked flue, flue over max length, vent terminal facing prevailing winds, Condensate backed up into HX’s

100 Freeze Protection 48W Ceramic heaters attached to the water pipes
Thermostat controlled when inlet air temperature drops to 41 DegF

101 Warranty Standard Warranty Residential usage 12 Years Heat Exchanger
5 Years Parts No labor allowance as standard

102 Website –
Tech Support x 3 – West Coast – East Coast Website –

103 Thank you Any Questions

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