Navien NP-180 Service Manual Download Page 170

Page: 170 / 179

©N

avien

erica

nc. 2010

NR/NP

series service Manual

Versi

n 2.0

Navien Part No.

Description

Remark

BH2422036A

BH1612007A

BH1705006A

BH1611006A

BH1603002A

BH1612008A

BH2507507E

BH2507508D

BH2507474D

BH1402001A

BH2505423A

BH2507536C

BH2507537C

AAVC9EX00014A

“Non-A” Series

NR-A

NP-A

NP, NP-A

Packing ring (3/4")

Bolt M4 x 12L (STS)

Screw D4 x 6L

Bolt D4 x 10L (STS)

Bolt M3 x 5L

Bolt M4 x 14L (STS)

Water pipe adapter (A, Screw)

Water pipe adapter (A, Clip)

T-type adapter (clip)

Freeze protect switch

Freeze protect S/W bracket

3-Way valve inlet pipe

Motorized 2-way valve

100

102

104

107

108

109

110

111

112

113

114

118

Summary of Contents for NP-180

Page 1: ...d installer service agency or the gas supplier WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death...

Page 2: ......

Page 3: ...AUTIONS 12 2 PRODUCT INFORMATION 17 2 1 PRODUCT INFORMATION 17 2 2 LAYOUT AND KEY COMPONENTS 18 2 2 1 NR A Model 18 2 2 2 NP A Model 19 2 2 3 NR Model 20 2 2 4 NP Model 21 3 TECHNICAL DATA 22 3 1 GENE...

Page 4: ...Ass y 49 4 6 8 Ignition Transformer 50 4 6 9 APS 51 4 6 10 Manifold 52 4 6 11 Main Gas Valve 53 4 6 12 GPS 54 4 6 13 Burner 55 4 6 14 Water Adjustment Valve 56 4 6 15 Flow Sensor 57 4 6 16 Primary Hea...

Page 5: ...it breaker operates 127 6 INSPECTION 128 6 1 PREPARING THE WATER HEATER FOR INSPECTION 128 6 2 MEASURING GAS PRESSURE SETTING 129 6 2 1 How to Check Inlet Gas Pressure 129 6 2 2 Adjusting the Gas Air...

Page 6: ...3 way Valve A Series 154 8 2 17 2 way Valve NP A NP Series 155 8 2 18 Bypass Mixing Valve Non A Series 156 9 COMPONENTS DIAGRAM AND PART LIST 157 9 1 CASE DISASSEMBLE NR NP A NR NP 157 9 2 BURNER DIS...

Page 7: ...Navien America Inc 2010 NR NP series service Manual 5 Version 2 0 Revisions Version Description of changes Date 1 00 2 00 First Issue Format Revision 04 27 10 July 20 10...

Page 8: ...Navien will replace the defective component part s in accordance with the terms of this Limited Warranty if it fails in normal use and service during the Applicable Warranty Period The replacement co...

Page 9: ...alled in a Commercial application or Residential Combi application is Three 3 years from the Effective Date IF a NR unit is used in any Commercial application or Residential Combi application the Appl...

Page 10: ...he water heater Damages malfunctions or failures caused by abuse negligence alteration accident fire flood freezing lightning and other acts of God Heat Exchanger failures caused by operating the wate...

Page 11: ...is Manual Navien America Inc reserves all rights related to this manual This manual should be accessible only to technical service personal authorized by Navien America Inc Read and understand the saf...

Page 12: ...P 210A and NP 240A General name of NR 180 NR 210 and NR 240 General name of NP 180 NP 210 and NP 240 General name of NR A and NP A General name of NR and NP Natural Gas Propane Gas Air Pressure Air Pr...

Page 13: ...s situation which if not avoided could result in property damage 1 3 Symbols Used in the Instructions The following symbols are used throughout the instructions to bring attention to important informa...

Page 14: ...NOT place anything in or around the vent terminals that could obstruct the air flow in and out of the water heater such as a clothes line DANGER Keep flammable products far away from heater in approv...

Page 15: ...water heater if any of the vent pipes vent elbows and or the water heater DANGER HOT WATER TEMPERATURE SETTING Water temperature over 125 can cause severe burns instantly or death from scalds Househol...

Page 16: ...han air and will settle on the floor Do not smoke Extinguish any open flames and sparks Do not operate light switches or electrical equipment switches Do not use any phone in your building Open the wi...

Page 17: ...ter servicing Improper adjustment alteration service or maintenance can cause property damage personal injury or death To prevent scalding always check the temperature of the hot water afterservicing...

Page 18: ...cause abnormal combustion and water heater malfunction Be sure to use 120 VAD 60 Hz minimum 2 A current Using abnormally high or low AC voltage may cause abnormal operation and may reduce the life ex...

Page 19: ...optional built in Circulation Pump and a Mini Buffer Tank In addition depending on the heat capacity each model is divided into three types 180 210 and240 Items NP NR A Series 180 210 240 Non A Series...

Page 20: ...PCB Board NACR1GS32410 20 Primary H E 6 Circulation Pump NAPU9GLPCT01 21 Ignition Transformer BH1201041D 7 DHW Supply Adapter BH2507348B 22 APS Venturi BH2501413A 8 3 Way Valve BH2507467C 23 Manifold...

Page 21: ...ition Trans BH1201041D 6 Circulation Pump NAPU9GLPCT01 22 APS Venturi BH2501413A 7 DHW Supply Adapter BH2507348B 23 Manifold PABCR180AMF_001 8 3 Way Valve BH2507467C 24 Burner PABNCN30KDBN_003 9 DHW I...

Page 22: ...ns BH1201041D 6 Heater BH1501047B 22 APS Venturi BH2501413A 7 Heater Clip BH2507447A 23 Manifold PABCR180AMF_001 8 DHW Supply Adapter BH2507348B 24 Burner PABNCN30KDBN_003 9 DHW Inlet Adapter BH250746...

Page 23: ...6 Heater BH1501047B 22 APS Venturi BH2501413A 7 Heater Clip BH2507447A 23 Manifold PABCR180AMF_001 8 DHW Supply Adapter BH2507348B 24 Burner PABNCN30KDBN_003 9 DHW Inlet Adapter BH2507469A 25 APS NASS...

Page 24: ...5 37 85 3 Thermisters In Out 1 Out 2 4 Thermisters In Out 1 Out 2 Mixing Auto Firing System Internal or External Recirculation Ceramic Heaters Cold Water 3 4 NPT Hot Water 3 4 NPT Recircualation 3 4 N...

Page 25: ...ce Manual 23 Version 2 0 3 2 Dimensions 3 2 1 NR A NP A Model A B C D E F 1 Connection Diameter Description Diameter 3 3 3 4 3 4 3 4 3 4 Exhaust Air Intake Hot Water Outlet Recirculation Inlet Cold Wa...

Page 26: ...010 NR NP series service Manual 24 Version 2 0 A B C D E 1 Connection Diameter Description Diameter 3 3 3 4 3 4 3 4 Exhaust Air Intake Hot Water Outlet Cold Water Inlet Gas Connection 2 Dimensions Mod...

Page 27: ...4 1 Schematic and Flow Diagram 4 1 1 NR A Model Hotwater supply Coldwater supply Fuelgas inlet Recirculation Exhaust pipe intake air duct Fan motor Manifold Burner Primaty H E Buffer tank Secondary H...

Page 28: ...ion 2 0 4 1 2 NP A Model Hotwater supply Coldwater supply Fuelgas inlet Recirculation Exhaust pipe intake air duct Fan motor Manifold Burner PrimatyH E Buffertank SecondaryH E Wateradjustmentv v Flows...

Page 29: ...ries service Manual 27 Version 2 0 4 1 3 NR Model Hotwater supply Coldwater supply Fuelgas inlet Exhaust pipe intake air duct Fan motor Manifold Burner PrimatyH E BypassMixingv v SecondaryH E Wateradj...

Page 30: ...service Manual 28 Version 2 0 4 1 3 NR Model Hotwater supply Coldwater supply Fuelgas inlet Exhaust pipe Intake air duct Fan motor Manifold Burner PrimatyH E BypassMixingv v SecondaryH E Wateradjustm...

Page 31: ...gniter OFF GV Igniter Power OFF Flame ON Flow Sensor 0 53 GPM Lock out 004E Lock out 015E Lock out 027E Lock out 009E Lock out 010E Flame On Pre Purge NoAir Check APS normal Watch dog ON Burner Start...

Page 32: ...ssure APS normal GPS normal D GPS normal MGV ON Igniter ON MV ON Flame ON during 10sec Igniter ON for 1sec after Flame ON Igniter OFF Igniter ON Burner Operation Flow Sensor 0 53 GPM Flame OFF B D Loc...

Page 33: ...out 015E HC minimum range HC minimum Burner Operation NO NO NO NO NO NO NO NO YES YES YES YES YES YES YES Faucet Close SV1 OFF SV2 OFF SGV1 OFF SGV2 OFF HC minimum range SV1 ON SV2 OFF SGV2 OFF HC mi...

Page 34: ...mistor 2 248 Thermistor Connection Abnormal High Limit Switch 2 Open Lock out 001E Lock out Lock out 007E Lock out 008E Lock out 015E Lock out 016E Lock out 021E Lock out 022E Lock out 030E Lock out 0...

Page 35: ...nition Spark igniter stops sparking 3 Normal Operation PCB monitors flame rod fan motor frequency outlet water temperature PCB temperature set point and water flow rate Main Gas control valve modulate...

Page 36: ...3 Stage Minimum OFF ON OFF ON OFF OFF ON ON Model Selection Dip Switch No 6 5 NR NP 180 NR NP 180A NR NP 210 NR NP 210A NR NP 180 NR NP 180A OFF ON OFF OFF OFF ON Function No 1 2 3 4 5 6 Burner Operat...

Page 37: ...ure Selection Factory setting ON Description OFF 2 Dip Switches With Pump NR 180A NR 210A NR 240A NP 180A NP 210A NP 240A Without Pump NR 180 NR 210 NR 240 NP 180 NP 210 NP 240 No Recirculation Extern...

Page 38: ...Navien America Inc 2010 NR NP series service Manual 36 Version 2 0 4 4 Wiring Diagram 4 4 1 NR A Model...

Page 39: ...Navien America Inc 2010 NR NP series service Manual 37 Version 2 0 4 4 2 NP A Model...

Page 40: ...Navien America Inc 2010 NR NP series service Manual 38 Version 2 0 4 4 3 NR Model...

Page 41: ...Navien America Inc 2010 NR NP series service Manual 39 Version 2 0 4 4 4 NP Model...

Page 42: ...Navien America Inc 2010 NR NP series service Manual 40 Version 2 0 4 5 Electrical Diagnostic Points A B C D E F G H K L M N O P Q R S I J T...

Page 43: ...cording to temperature Normally input pulse Confirm rms voltage as measuring DC meter Normally input pulse Confirm rms voltage as measuring DC meter Currency changes as controlling gas volume after op...

Page 44: ...alve P E Flame Rod Power trans AC150V Power trans AC120V Motorized 2 way Valve Confirm output voltage Confirm if voltage flows without any relations with the fan operating Confirm if voltage flows wit...

Page 45: ...each component and performance unit 1 Malfunctioning PCB 1 A component may not operate within the unit In most cases of PCB failure the whole unit does not operate at all E015 1 Visual inspection Con...

Page 46: ...3 195 3 Detects excessive temperature within the unit especially around the heat exchanger and combustion chamber Upon detection communication between the PCB and gas valves will sever shutting down t...

Page 47: ...ed with this transformer 1 The unit does not operate due to lack of power from transformer 2 A failed transformer can cause electrical damage to other electrical components within the unit N A 1 Visua...

Page 48: ...igh water temperature if switch fails 2 Unable to detect excessively high flue gas temperature if switch fails 1 Unable to shut down the water heater if the water temperature from the heat exchanger e...

Page 49: ...e flue gas temperature from the exhaust duct exceeds 149 65 E007 E008 E021 E022 E032 E033 E041 E042 1 Visual inspection Connection and or breakage of wires 2 Voltage check Check range of voltage shown...

Page 50: ...is disassembled 3 Connection terminal assembly defectiveness 1 Unstable combustion condition 2 Unit vibrating and making a noise 3 The water heater is not operating E009 E010 E027 1 Visual inspection...

Page 51: ...the ignition process 2 Makes attempts to ignite at all times 1 The unit cannot ignite during the ignition process and E003 or E004 error codes will display 2 No effects on the unit however the durabil...

Page 52: ...s to ignite at all times 1 The unit cannot ignite during the ignition process and E003 or E004 error codes will display 2 No effects on the unit however the durability of the igniter wears down E003 E...

Page 53: ...ntity of air supply operate with GPS 1 The combustion noise occurs 2 Imperfect and or lifting Flame occurs 1 The water heater is not operating 2 Excess carbon monoxide emissions E009 E010 E027 1 Visua...

Page 54: ...w from the manifold which can cause poor combustion in the combustion chamber In this case the flame rod will detect an improper flame condition and the PCB board will take safety measures 2 Gas leaka...

Page 55: ...rom the valves 2 Unable to open close main and solenoid gas valve 3 Unable to modulate the gas flow proportional gas valve 1 Gas leak from the unit 2 No flames 3 No operation of the unit 4 Excess carb...

Page 56: ...erly even when there s low gas pressure supply within certain range of gas pressure 95 because GPS makes if possible to check and modulate gas ratio for stable combustion 1 Gas leak from the valves 1...

Page 57: ...ustion 2 Dust or soot deposit on the burner fin surface 3 Gas leakage from burners 1 An unexpected combustion 2 Unstable flame conditions and or flame loss 3 Ignition failure E003 E004 E012 Visual ins...

Page 58: ...ng once detecting water leakage 2 No flames 3 No operation of the unit 4 Temperature fluctuations in the hot water outlet E034 1 Visual inspection Connection and or breakage of wires Clean the Domesti...

Page 59: ...re any water flow rate 2 Water leakage from the water flow sensor 1 Ignition sequence does not start 2 Stop operating once detecting water leakage E039 1 Visual inspection Connection and or breakage o...

Page 60: ...it minimizes the heat loss 1 Water and or exhaust gas leakage through a crack 2 Improper heat transfer can cause the water in heat exchanger to boil 1 The unit will stop operating once detecting wate...

Page 61: ...chamber and it minimizes the heat loss 1 Water and or exhaust gas leakage through a crack 2 Improper heat transfer can cause the water in heat exchanger to boil 1 The unit will stop operating once det...

Page 62: ...minimum flow rate with internal circulator 2 Applied to the types of NR A and NP A only 1 Water leakage from the mini buffer tank 1 Stop operating once detecting water leakage 2 Temperature fluctuati...

Page 63: ...ixtures quickly resulting in water conservation 3 Applied to the model of NR A and NP A only 1 Unable to detect or measure water flow rate Only circulation mode 1 The water heater freezing 2 Abnormal...

Page 64: ...functions differ and cannot be substituted for each other 1 Water leakage from the bypass mixing valve 2 The valve cannot modulate or make open close positions 1 Stop operating once detecting water le...

Page 65: ...t water outlet Thermistor short 1 Check the Thermistor 2 Look for short or water in connection 3 Replace the Thermistor E008 Manual Abnormal fan motor activity 1 Check and clean the air filter1 part 1...

Page 66: ...e at connection E032 Abnormal the Water Adjustment Valve Abnormal activity of the gas pressure sensor Abnormal activity of the gas pressure sensor 1 Check to make sure wire connections are secure 2 Ch...

Page 67: ...as the combustion is stopped the system displays an error message and does not start combustion until the temperature goes below 185 85 or 176 80 at the input of the heat exchanger The error message O...

Page 68: ...higher than it actually is due to a defective sensor Check if the deviation of temperature is large due to a defective temperature sensor 2 Pull out the hot water output temperature sensor connector...

Page 69: ...ransformer ignition state input power AC 102 132 V Check the operation of the gas control valve DC 83 120 V coil short circuit solenoid valve Check the flame detecting rod and wiring and grounding Che...

Page 70: ...restart Yes Check the voltage between two wires of CN 17 Same as supply voltage 97 138 VAC Replace PCB No Yes Is the igniter electrode clean Is the igniter electrode damaged Yes No Clean or replace ig...

Page 71: ...ve proper voltage Is the tube which is connected with modulating gas valve properly installed No No Check connector Yes Check the voltage between two brown wires 1 2 of CN 15 83 120VDC Check the resis...

Page 72: ...e stop of the boiler Dynamic pressure Gas pressure at boiler max combustion 3rd stage MAX combustion setting DIP S W1 1 ON 5 Excessive force in fastening nuts at installation of gas pipe may move the...

Page 73: ...V If there is no trouble in the input power to the ignition transformer replace the ignition transformer Replace the PCB if there is a trouble in the power supply to the ignition transformer Check the...

Page 74: ...s a case of defective grounding due to the painting of exterior base Therefore remove the painting in the screw fastening part and reconnect Or use a tester to measure the flame sensing current normal...

Page 75: ...nition fail occurs due to a problem in supplying gas or adjusting gas pressure cover the blower inlet hole with a hand at the ignition stage If a flame occurs check the gas supply system Incorrect DIP...

Page 76: ...flue installation 1 Remove 4 screws and remove the ignition transformer and the venture 2 Remove 6 screws 2 under and 4 upper 3 Remove 2 manifold fixing screws 4 Remove multi stage valve 5 Use a scre...

Page 77: ...e flame If a flame signal is detected continuously for 6 seconds when the system performs post purge as fuel supply is stopped a false flame error 04E automatically cleared is displayed on the thermos...

Page 78: ...after combustion is stopped Spark discharges from electrode to flame sensor at ignition Replace or correct location of flame detecting rod Gas may leak as the main gas valve is pushed by the gas supp...

Page 79: ...etected continuously for 6 seconds when the system performs post purge as fuel supply is stopped a false flame error 04E automatically cleared is displayed on the thermostat and the system performs co...

Page 80: ...ure sensor is open and if the connector is connected properly Measure the resistance of the temperature sensor Defective if it is 30 or higher If the resistance is abnormal replace the temperature sen...

Page 81: ...ys the error message 08E on the remote controller and the PCB Hot water output temperature sensor 1 Check if the hot water temperature sensor connector is wet due to any reason including leakage 2 Rep...

Page 82: ...r or the PCB harness terminal is wet due to any reason including leakage Use a tester to measure the temperature sensor resistance If the resistance is abnormal replace the temperature sensor abnormal...

Page 83: ...starts to run and displays the error message 09E cleared manually in the following cases 1 If the RPM signal is 400 or lower at pre purge the system repeats pre purge 10 times If the RPM remains 400...

Page 84: ...moter have normal operation voltage Yes No Check power and connector Is there any pulse output from the fan motor Yes No Replace fan assembly Replace PCB Check the voltage between black and white wir...

Page 85: ...d normally 3 If the trouble continues despite the checking of above items replace the blower 1 If RPM is significantly low while the blower works and the power supply is normal replace the blower 2 Ch...

Page 86: ...or PCB The system senses the air volume and the RPM signal and displays 10E on the indoor thermostat in the following cases 1 During pre purge If the air volume sensor voltage fails to reach the stand...

Page 87: ...put from the fan motor Yes No Replace APS Check the voltage between black and white wire of CN 6 0 3 4 0VDC APS Air Pressure Sensor Check the voltage between black and red wire of CN 6 4 5 5 5VDC Does...

Page 88: ...hose is clogged Check if the hose is clogged with water remained from installation 2 Check if the venturi burner hole is clogged with soot or foreign substance Blow air with mouth through the air pres...

Page 89: ...gh the supply pipe If the exhaust gas glows in through the air supply pipe imperfect combustion may cause 10E due to noise and instable APS and RPM Check the installation of flue and if the standard f...

Page 90: ...6 180 MODEL 10 5 W C LP 8 9 180 MODEL 13 5 W C 2 Check the Gas meter Capacity 3 Check the Gas Pipe Diameter 3 4 4 Check the controller DIP S W capacity setting 5 3 stage MIN differential gas pressure...

Page 91: ...c pressure Gas supply pressure as the boiler is stopped Check the dynamic pressure Gas supply pressure at boiler MAX combustion 4 Check the gas pipe connector Excessive force in fastening nuts at inst...

Page 92: ...y from inside wall of the nozzle Flame blowout due to increased blower RPM caused by air pressure sensor standard value error Replace the air pressure sensor Flame may be blown out if the stage is swi...

Page 93: ...tester if the PCB is in the rated voltage AC 102 132 V 3 Disconnect the ground wire and check the PCB Check method Description Error Gas warning Defective PCB Power supply error Power supply groundin...

Page 94: ...ensor signal is detected within 10 min after the combustion is stopped no error is displayed and the system does not start combustion until the overheat sensor is returned to normal Is HTL normally op...

Page 95: ...ted Separate inlet outlet pipe of the main heat exchanger and blow air with mouth to check if the pipe is clogged Check with a tester if the temperature fuse is disconnected If the fuse is disconnecte...

Page 96: ...Measure the temperature sensor resistance and determine if the sensor is defective 1 If the Max switch 1 is on Set the switch to the normal operation position 2 Sudden increase of temperature due to P...

Page 97: ...sor 3 Replace the PCB Navien America Inc 2010 NR NP series service Manual 95 Version 2 0 Check method Error Defective sensor Other trouble Defective temperature sensor connector Temperature sensor Def...

Page 98: ...ared automatically on the remote controller and the PCB The boiler maintains the Safety Shutdown status 1 Check if the heat exchanger input temperature sensor connector is wet due to any reason includ...

Page 99: ...if the hot water tem perature sensor is open Check if the temperature sensor connector or the PCB harness terminal is wet due to any reason including leakage Check the resistance of the temperature se...

Page 100: ...Yes No Replace APS Check Connector During fan motor operation is the output voltage of APS normal Yes No Replace APS Check the voltage between black and white wire of CN 6 1 4VDC Check the voltage be...

Page 101: ...ed on the PCB AD value A 150 150 Check the value at min max of the combustion specification table Replace the air pressure sensor if an error occurs standard value 500 or higher 2 Check the air volume...

Page 102: ...manually othe room controller and the PCB Overheat controller operating temperature 149 The boiler switches into Lock Out and performs post purge continuously and operates the pump Is HTL normally ope...

Page 103: ...exhaust gas temperature caused by the defective heat exchanger 2 The error occurs due to high temperature due to the heat leaked from the heat exchanger 3 Replace the heat exchanger Defective contact...

Page 104: ...3 Defective PCB 4 Check dipswitch settings Non A A Model Navien America Inc 2010 NR NP series service Manual 102 Version 2 0 Check method Error Defective sensor Other trouble Defective temperature se...

Page 105: ...cluding leakage 2 Replace the defected cold water temperature sensor 3 Replace the PCB Navien America Inc 2010 NR NP series service Manual 103 Version 2 0 Check method Error Defective sensor Other tro...

Page 106: ...water adjustment valve or PCB board the system displays 34E cleared automatically manually and switches into the Safety Shutdown mode Water adjustment valve close error The system commands opening of...

Page 107: ...r 2 Check the connector assembly and wiring state of the water adjustment valve feedback sensor 3 Check the water adjustment valve output value AD displayed on the PCB On the display F 15 or lower mea...

Page 108: ...water from the unit 2 Remove the top bottom clips of the water adjustment valve 3 Disassemble the motor and open the lid 4 Turn the water adjustment valve axis disk counterclockwise to the end 5 Pull...

Page 109: ...hose Check the gas pressure sensor If an error Open 0 1 0 1 V or lower Short circuit 4 5 0 2 V or higher is detected or if the gas pressure or hose is pulled out the system displays 35E cleared autom...

Page 110: ...s pressure sensor connector Check the gas pressure sensor input output voltage Operating voltage Black Blue DC 5 V Sensor output voltage Black White Open DC 0 1 0 1 V or lower Short circuit DC 4 5 0 2...

Page 111: ...operate normally when the flowmeter works 2 If a communication error occurs in the master water heater all the slave water heaters operate individually Navien America Inc 2010 NR NP series service Man...

Page 112: ...r enters the Lock Out mode gas valve and ignition transformer closed and closes the flow control valve to prevent further water leak For the cascade system 1 If the water leak signal is sensed in one...

Page 113: ...ontact between the water leak sensor wires and with the water heater enclosure base 1 Check the leaking part and repair the part 2 Check molex connection on board for moisture Other trouble Defective...

Page 114: ...nd check if the system senses the flow If the flow is not sensed after the pump is started the system displays 38E cleared automatically on the remote controller and the PCB Is there clod water supply...

Page 115: ...fective if the water flow displayed is 00 0 when water is discharged from the hot water tap 1 Check if the pump works normally 2 Check the pump power cable connector and if the wiring is performed nor...

Page 116: ...em and faucet open Check supply cold water 1 Check the supply of cold water Frozen locked valve 2 Defective flow sensor 3 Defective PCB As one or more units are operating in the cascade system if no f...

Page 117: ...ow sensor Operating voltage Black Red Defective PCB if DC 5 V is not supplied 8 Replace the flow sensor if no flow is detected while the operating voltage is normal Other trouble Defective PCB If the...

Page 118: ...the flow sensor If the impeller rotates normally replace the hall sensor 4 If the impeller does not rotate disassemble it by pushing the axis with a driver 5 If you push the axis the impeller housing...

Page 119: ...r than the hot water temperature by 5 C the system considers incorrect assembly of the hot water temperature sensor and the heat exchanger input temperature sensor stops combustion and displays an err...

Page 120: ...ensor assembly error Defective temperature sensor Check the assembly of each temperature sensor connector Measure the temperature sensor resistance Replace the temperature sensor if the value is out o...

Page 121: ...is noticed in abnormal condition display 45E Display error code when bypass Mixing valve cannot close Display 16 01 at PCB generally step motor of bypass mixing valve is in abnormal condition Display...

Page 122: ...tarting Dose Mixing trans have normal output voltage Yes Yes Yes No Replace Mixing trans Replace Bypass Mixing Valve operation checking supply power turn R C on off stop the burner operation Check the...

Page 123: ...onnection of wire mixing trans and PCB Output voltage of black white wire of CN24 DC 0 13V is not change display 45E 16 02 during checking operation Check the connection of wire to wire connector and...

Page 124: ...anually If fire breaks out 5 times or more and ignition fails during the combustion after the low gas error is detected If the target APS is out of a specific value range during the combustion with th...

Page 125: ...ctive gas regulator 3 Lack of gas in the container 4 Clogged pipe foreign substance 1 Check the gas pressure sensor value AD value displayed on the controller P 100 100 Check the value at min max of t...

Page 126: ...PCB 1 Gas differential pressure adjustment error Adjust differential pressure with the pressure adjusting screw on the main gas valve DIP S W 1 2 ON S W 3 MIN If noise occurs at standard value adjust...

Page 127: ...stance Set DIP S W 1 2 to ON 3 stage MIN and check the flame Compare flame of Burner at combustion section of stages 1 2 and 3 Check the nozzle if there is a comparatively unbalanced burner section 1...

Page 128: ...k due to foreign substance If the impeller rotates normally replace the hall sensor of the flow sensor The sensor may be reused temporarily after cleaning but replacement must be considered preferenti...

Page 129: ...er Be careful that wire is not pressed down when assembling the main gas valve Check if the wire is fixed and well adjusted on the main side of the heat exchanger If circuit breaker operates during th...

Page 130: ...e advise you to offer your customer an annual inspection Precautions on security before working Inspection items and entire procedures Tools required when inspection Volt Ohm Amp meter with test probe...

Page 131: ...re are no gas leaks 6 Open multiple fixtures that have high flow rates bathtub showers kitchen sink to ramp the water heater up to its maximum burn 7 When the Navien water heater is at maximum burn ch...

Page 132: ...he manometer Compare the gas air pressure difference with FACTORY setting chart in bottom page When the gas air pressure difference is out of standard range adjust the pressure difference by rotating...

Page 133: ...Natural Gas Propane Gas Natural Gas Propane Gas 0 87 0 06 W C 1 57 0 06 W C 0 67 0 06 W C 1 30 0 08 W C 0 67 0 06 W C 1 30 0 08 W C 2 68 0 08 W C 4 60 0 08 W C 1 73 0 08 W C 3 19 0 08 W C 2 20 0 08 W...

Page 134: ...heater Describe precautions before maintenance and show tools required when maintenance Draining the water in the waterway Drain the water in the waterway according to the following figure Also clean...

Page 135: ...ir filter from the bottom of the intake pipe by pulling it out towards the front 3 Remove the filter from the plastic assembly 4 Clean it with a toothbrush and water 5 Re fit the screen in to the plas...

Page 136: ...approximately 4 gallons of virgin food grade white vinegar or critic acid pail 6 Place the drain hose H3 and the hose H2 to the pump inlet into the cleaning solution 7 Open both service valves s V1 an...

Page 137: ...When performing maintenance and of servicing the water heater always turn off the electric power gas and water shut off valve Wait for the water heater to become cool Be careful to avoid injury to yo...

Page 138: ...tom base 5 Remove the all connecting housing into the PCB 8 Pull out the PCB 9 Attach the new PCB tighten screws 10 Connect the all connecting housing into the PCB 11 Install front panel using 4 four...

Page 139: ...left side 6 Remove the capsule A s B C connected to the power cable 8 New fuse into the part C and assemble B C 9 Rotate the PCB to the right side 10 Fix the PCB right side screw from bottom base 11 I...

Page 140: ...supply 4 Loosen the PCB 2 screw from bottom base 5 Pull out the PCB refer to 8 2 1 PCB 6 Loosen the 2 screws from transformer 7 Pull out the transformer 8 Replace with new transformer 9 Tighten the 2...

Page 141: ...he fan to be replaced 9 Fix the three screws of the fan 10 Attach the harness housing to the fan assembly 11 Install front panel using 4 four screws 12 Turn on water supply power supply and gas supply...

Page 142: ...r Cable 9 Pull out the igniter 10 Attach the new ignition electrode and tighten screws 11 Connect the trans cable and flame rod cable into the ignition electrode and flame rod 12 Attach the fan to be...

Page 143: ...ble refer to 8 2 6 Flame Rod 7 Remove the igniter connecting housing into the PCB 9 Pull out the Ignition Transformer 10 Attach the new ignition transformer tighten screws 11 Connect the Ignition tran...

Page 144: ...sensor lowerside 2 screw from burner assemble 8 Pull out the air pressure sensor 9 Attach the new air pressure sensor tighten screws 10 Connect the air pressure sensor tube 11 Connect the air pressure...

Page 145: ...om bottom base 5 Pull out the PCB refer to 8 2 1 PCB 6 Loosen the gas pipe from gas valve lower and Manifold upper 9 Remove the wire harness from the 2 solenoids 10 Pull out the manifold assembly 11 R...

Page 146: ...Oring where the assembly attaches to the gas connection Make sure the old Oring removed and discarded 14 Replace the PCB 15 Install front panel using 4 four screws 16 Turn on water supply power suppl...

Page 147: ...ack tube and remove the wire harness connector from the 2 solenoid valve and modulating valve 9 Remove the gas valve screws from the gas adapter 10 Pull out the gas valve 11 Positioned gas valve 12 At...

Page 148: ...n a gas leak or explosion WARNING 15 Replace the PCB 16 Install front panel using 4 four screws 17 Turn on water supply power supply and gas supply 18 Perform the measuring of gas pressure setting pro...

Page 149: ...pressure sensor 10 Assemble the gas pressure sensor 2 tubes 11 Attach the gas pressure sensor and secured with 2 screws 12 Replace the PCB refer to 8 2 1 PCB 13 Install front panel using 4 four screw...

Page 150: ...densation trap 12 Connects the condensation trap hose 13 Attach the condensation trap and secured with three screws 14 Replace the PCB refer to 8 2 1 PCB 15 Install front panel using 4 four screws 16...

Page 151: ...ve 10 Replace with new water adjustment valve 11 Replace the water adjustment valve into the cold water inlet adapter 12 Replace the water adjustment outlet pipe into the water adjustment valve 13 Rep...

Page 152: ...r 8 Replace with new flow sensor 9 Connect the flow sensor wire housing into the PCB 10 Reseat the flow sensor into the cold water inlet pipe and reattach the stainless clip 11 Reseat the non threaded...

Page 153: ...10 Replace the Oring in service parts included the buffer tank 11 Reseat the buffer tank from the cop per stainless pipe and plastic adapter 12 Replace the fastener A A and fastener F B 13 Tighten the...

Page 154: ...ance 4 Loosen the PCB 2 screw from bottom base 5 Remove the pump connecting housing into the PCB 6 Pull out the PCB refer to 8 2 1 PCB 7 Open the drain plug on the pump 8 Loosen the screw from the 3 w...

Page 155: ...fitting At this time be watchful the red gasket ring 19 Close the drain plug and tighten screws from bottom base 20 Replace the PCB refer to 8 2 1 PCB 21 Install front panel using 4 four screws 22 Tur...

Page 156: ...lve 11 Replace with new 3 way valve secured it 12 Tighten the 3 way valve 3 screws from bottom base 13 Replace the circulation pipe into the 3 way valve 14 Replace the stainless clip fastener D 14 Rep...

Page 157: ...2 stainless clips fastener D 9 Pull out the 2 way valve 10 Replace with new 2 way valve 11 Replace the 2 way valve into the cold water inlet adapter 12 Replace the 2 way valve outlet pipe into the 2 w...

Page 158: ...ull out the mixing valve 10 Replace with new mixing valve 11 Replace the mixing valve into the primary H E inlet adapter 12 Replace the mixing valve outlet pipe into the mixing valve 13 Replace the 2...

Page 159: ...Navien America Inc 2010 NR NP series service Manual 157 Version 2 0 9 Components Diagram and Part List 9 1 Case Disassemble NR NP A NR NP...

Page 160: ...26002A BH1426003A BH1705007A BH1603009A BH1708004A BH1402001A BH2505423A Case Cover Navien Logo Case upper bracket Case lower bracket PCB board Intake air duct Intake air duct packing Intake air filte...

Page 161: ...Navien America Inc 2010 NR NP series service Manual 159 Version 2 0 9 2 Burner Disassemble NR NP A NR NP...

Page 162: ...01413A BH2405031A BH1419012A BH1419013A BH1201041D 210 240 NG 180 NG 210 240 Propane 180 Propane 180 NG 210 240 NG 180 Propane 210 240 Propane NG Propane NG Propane 180 NG 210 240 NG 180 Propane 210 2...

Page 163: ...05007A BH1705001A BH1603006A BH1710001A BH1612005A BH1701030A BH1708003A BH1701031A BH1611006A BH1611005A BH1611001A 180 210 240 180 210 240 180 210 240 Tube Tube Tube Tube O ring O ring Screw D4 x 8L...

Page 164: ...Navien America Inc 2010 NR NP series service Manual 162 Version 2 0 9 3 Water Way Disassemble NR A...

Page 165: ...Navien America Inc 2010 NR NP series service Manual 163 Version 2 0 9 4 Water Way Disassemble NR...

Page 166: ...Navien America Inc 2010 NR NP series service Manual 164 Version 2 0 9 5 Water Way Disassemble NP A...

Page 167: ...Navien America Inc 2010 NR NP series service Manual 165 Version 2 0 9 5 Water Way Disassemble NP...

Page 168: ...P 180A NP 210 240A NR 180 NR 210 240 NP 180 NP 210 240 NR A NR NP A NP A Series A Series Non A Series A Series Non A Series Non A Series A Series NR A NP A NR NP A Series Flow sensor Water adjustment...

Page 169: ...BH1603015A BH0913004D A Series A Series Non A Series NR A NP A NR 180 NR 210 240 NP 180 NP 210 240 A Series NR 180A NR 210 240A NP 180A NP 210 240A A Series A Series A Series NR 180A NR 210 240A NP 1...

Page 170: ...1A BH2505423A BH2507536C BH2507537C AAVC9EX00014A NP Non A Series Non A Series NR A NP A NP NP A Packing ring 3 4 Bolt M4 x 12L STS Screw D4 x 6L Bolt D4 x 10L STS Bolt M3 x 5L Bolt M4 x 14L STS Water...

Page 171: ...g Out a Water Leak Test in Operation Carrying out a gas leak test in operation Checking Hot Water Temperature and Flow Checking Noise Checking venting systems Checking the remote controller CAUTION Se...

Page 172: ...and Adjusting the Gas Air Ratio Checking Flue Gas Carrying Out a Water Leak Test in Operation Carrying Out a Gas Leak Test in Operation Checking Hot Water Temperature and Flow Checking Noise Checking...

Page 173: ...0 10 3 Maintenanc Report Draining the Water Heater and Cleaning the Inlet Water Filter Cleaning the Return Filter Checking the Intake Air Filter Flushing the Heat Exchanger Replacement of Parts YES NO...

Page 174: ...Navien America Inc 2010 NR NP series service Manual 172 Version 2 0 Memo...

Page 175: ...Memo Navien America Inc 2010 NR NP series service Manual 173 Version 2 0...

Page 176: ...Memo Navien America Inc 2010 NR NP series service Manual 174 Version 2 0...

Page 177: ...Memo Navien America Inc 2010 NR NP series service Manual 175 Version 2 0...

Page 178: ...Memo Navien America Inc 2010 NR NP series service Manual 176 Version 2 0...

Page 179: ......

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