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Navien NPN, Installation & Operation Manual

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Navien NPN Installation & Operation Manual Download Page 10

9

About the Water Heater

2.5    Components

The following diagram shows the key components of the water heater. Component assembly diagrams and 

particular parts lists are included in the Appendixes.

Intake Air/Exhaust Duct

Condensate Drain

STS Heat Exchanger

NaviTech

TM

 Burner

Ignitor&Flame Rod

Front Panel

PCB

Water Inlet Filter

Gas Inlet Fitting

Fan Motor

Ignition Transformer

APS (Air Pressure Sensor)

DHW Supply Fitting

Cold Water Inlet Adapter

[NPN-160U/180U/199U]

Summary of Contents for NPN

Page 1: ...ater Contact a licensed professional for the affected system for example a plumber or electrician When you contactTechnical Support please have the following information at hand Model number Serial nu...

Page 2: ...ceagencyorthegassupplier Theinstallationmustconformwithlocalcodesor intheabsenceoflocalcodes theNationalFuelGas Code ANSIZ223 1 NFPA54 Whenapplicable theinstallationmustconformwiththeManufacturedHomeC...

Page 3: ...r Heater 14 3 1 Choosing an Installation Location 14 3 2 Mounting the Water Heater to the Wall 18 3 3 Connecting the Gas Supply 19 3 4 Connecting the Water Supply 25 3 5 Venting the Water Heater Indoo...

Page 4: ...se landline phones From a neighbor s phone call your gas provider and follow their instructions If you cannot reach your gas provider call the fire department Do not use or store flammable products su...

Page 5: ...r heater has been approved for use in the USA only Using the water heater in any other country will void the manufacturer s warranty WARNING Do not store or use gasoline or other flammable liquids nea...

Page 6: ...burns Use the lowest operating temperature setting necessary to provide comfortably hot water If your household has children or elderly or disabled residents using a lower temperature setting is reco...

Page 7: ...aps Remote Controller outdoor models only 2 2 Accessories The following optional accessories are available for the water heater Remote Controller indoor models only Plumb Easy Valve Set with Pressure...

Page 8: ...25 kg 55 lbs 25 kg 60 lbs 27 kg 60 lbs 27 kg Installation Type Indoor Wall Hung Vent Kit Optional for Outdoor Only Outdoor Wall Hung Venting Type Forced Draft Direct Vent Indoor only Ignition Electro...

Page 9: ...aintenance a b c d e f g h i j k a f h c i d j e k For indoor models For outdoor models a Error g Master Unit A code will appear on the display Cascade operation b Hot Water Recirculation h Display Re...

Page 10: ...rams and particular parts lists are included in the Appendixes Intake Air Exhaust Duct Condensate Drain STS Heat Exchanger NaviTechTM Burner Ignitor Flame Rod Front Panel PCB Water Inlet Filter Gas In...

Page 11: ...S Heat Exchanger Ignitor Flame Rod NaviTechTM Burner Front Panel PCB Water Inlet Filter Gas Inlet Fitting Fan Motor Ignition Transformer APS Air Pressure Sensor DHW Supply Fitting Cold Water Inlet Ada...

Page 12: ...Description Diameter A Exhaust Gas Vent 3 in B Air Intake 5 in C Hot Water Outlet 3 4 in D Cold Water Inlet 3 4 in E Gas Inlet 3 4 in F Condensate Drain 5 8 in OverheadView A B F 3 7 in 93 mm 7 in 17...

Page 13: ...ctions Description Diameter A Hot Water Outlet 3 4 in B Cold Water Inlet 3 4 in C Gas Inlet 3 4 in OverheadView 9 4 in 239 1mm 0 4 in 11 2 mm Supply Connections A C B 4 2 in 105 7 mm 14 in 356 mm 2 7...

Page 14: ...ble in the installation location If the water heater does not match each of these ratings do not install the water heater If conversion to Propane Gas or Natural Gas is required the Gas conversion kit...

Page 15: ...mg l pH 6 5 to 8 5 Sulfate Up to 250 mg l Total Dissolved Solids TDS Up to 500 mg l Zinc Up to 5 mg l Chlorine Up to 4 mg l If your local water is hard please review the following recommended treatmen...

Page 16: ...omestic water supply enters the building Gas the installation location should be near where the gas supply enters the building Electricity the installation location should be near where the electrical...

Page 17: ...nts Do not enclose the vent termination Install the exhaust vent in an area that is free from obstructions and does not allow the exhaust to accumulate Do not install the water heater where moisture f...

Page 18: ...less steel heat exchanger gaskets and the flue and vent system In commercial locations do not install the water heater in areas with greasy fumes or heavy amounts of steam or take measures to prevent...

Page 19: ...ide the protective shipping base Install the water heater upright in the vertical position Installation in any other orientation will result in improper water heater operation and property damage and...

Page 20: ...akage and result in fire explosion property damage severe personal injury or death The appliance and its gas connection must be leak tested before placing the appliance in operation To avoid danger of...

Page 21: ...as leaks Union Gas Shutoff Valve Gas Supply Gas Inlet Adapter BottomView Full Size Gas Pipe Navien recommends connecting the water heater as the first water heater downstream of the gas meter to ensur...

Page 22: ...s ensure that the pipe s inner diameter and connector is sufficient to supply the required BTUs Also ensure that the flexible line has no crimps or tight bends in it as this will restrict gas flow Whe...

Page 23: ...532 2 in 4 020 2 760 2 220 1 900 1 680 1 520 1 400 1 300 1 220 1 160 1 020 2 1 2 in 6 400 4 400 3 530 3 020 2 680 2 430 2 230 2 080 1 950 1 840 1 630 3 in 11 300 7 780 6 250 5 350 4 740 4 290 3 950 3...

Page 24: ...d from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psi 3 5 kPa The appliance must be isolated from the gas supply piping system by closin...

Page 25: ...eater reaches its maximum firing rate check the inlet gas pressure reading on the manometer The gas pressure must fall within the ranges specified on page 23 2 Open a hot water faucet The water heater...

Page 26: ...necting the Water Supply The water fittings on the water heater are 3 4 in If the installation site only has 1 2 in plumbing throughout it is not necessary to upsize the water lines to 3 4 in When con...

Page 27: ...Air configurations cannot be used at the same time 3 4 2 External Pump Wire Connection An external pump may be connected to the water heater for recirculation applications When selecting a circulator...

Page 28: ...9E 4 Connect the external pump wiring connector to the connector socket on the PCB TB1 TB1 5 Put the PCB box back in its original place and secure it using the 2 mounting screws 6 Remove the plastic i...

Page 29: ...ss the Info button No Mode Display 1 Technical Information 2 Parameter Information 4 To return to the previous menu R D information menu press the Reset button once Items Name Description Display 12 P...

Page 30: ...ime Settings Mode 2 Once you enter the mode enter the parameter values and the item will start to flash 3 Press the or button in the Preheat Pump Output Time Settings Mode to change the value of the P...

Page 31: ...ation Do not plug the relief valve CAUTION To avoid potential property damage or personal injury check the pressure relief valve at least once every three years by manually operating the valve to ensu...

Page 32: ...collar to the vent termination by fully inserting the vent pipe into the water heater collar The vent pipe must be inserted 1 3 in 34 mm into the water heater collar Once fully inserted mark the vent...

Page 33: ...ry 4 ft 1 2 m horizontally and every 6 ft 1 83 m vertically WARNING The vent piece connected to the water heater must be secured by one self tapping screw Securing screw Eachpipemustbesecuredusingtwos...

Page 34: ...staller must use the fastening screws provided to secure the vent pipe to the collar as well as follow all other installation directions and requirements Over tightening of the fastening screws may pu...

Page 35: ...on instructions may cause the vent pipe to separate from the water heater which will result in excessive carbon monoxide emissions and extremely dangerous conditions which can lead to severe personal...

Page 36: ...line of the terminal As specified by the manufacturer E Clearance to unventilated soffit As specified by the manufacturer F Clearance to outside corner As specified by the manufacturer G Clearance to...

Page 37: ...G Clearance to inside corner As specified by the manufacturer H Clearance to each side of center line extended above meter regulator assembly As specified by the manufacturer I Clearance to service re...

Page 38: ...st 12 in 30 cm away from the inside corner of a wall If the adjacent wall is less than 12 in 30 cm in length the minimum required distance away from the inside corner will be equal to the length of th...

Page 39: ...m Note The Maximum Length does not include any elbows 3 5 4 Terminating the Vent Before installing the water heater determine what type of vent termination is appropriate for the installation locatio...

Page 40: ...87 Includes One Sidewall Termination One 90 Elbow TwoWall Plates ConcentricSidewallTerminationKit VentPipeExtention ReplacementGasket BlueSilicone Black EPDM Navien Part GXXX001898 Navien Part GXXX001...

Page 41: ...omponents Note Refer to the contact information of the manufacturer if necessary Manufacturer Metal Fab Tel 800 835 2830 E mail info mtlfab com Website www metal fabinc com Item Description 3CGV36 36...

Page 42: ...ndensate collector cap unless a condensate trap is attached If a condensate trap is not installed properly as explained above it could result in injury or death 5 1 in 130 mm The water heater will cre...

Page 43: ...electrical supply A junction box is provided underneath the water heater if a direct electrical connection is required The water heater must be electrically grounded If using the power plug ensure th...

Page 44: ...of the heat exchanger In cold weather areas where power failures are common you must completely drain the water heater to prevent damage if the power will be off for any extended period of time A bat...

Page 45: ...wo sets of DIP switches on the circuit board configure the water heater s model settings These configurations are set at the factory and should not be changed 3 7 2 Setting the Front Panel DIP Switche...

Page 46: ...xternal Pump Connected Preheating 3 ON 4 Display Temperature Unit Celsius 4 ON Fahrenheit 4 OFF 5 Well Pump Well Pump Operation 5 ON Do Not Use Well Pump 5 OFF 6 DHW Storage Tank Storage Tank Operatio...

Page 47: ...extension cable to the port on the front panel of the water heater 2 Pass the other end of the extension cable through the hole in the bracket 3 Connect the end of the extension cable to the cable co...

Page 48: ...r settings Recirculation ON Up button Increase the temperature or value Down button Decrease the temperature or value Lock button Locks the other button operations Power button Turns the remote contro...

Page 49: ...lly Setting the Multi Remote Controller System If you turn on the water heater with the front panel connected to two remote controllers one of the controllers is set to the main controller randomly Th...

Page 50: ...multi remote controllers Press the Preheat Timer button and Lock button simultaneously for 2 seconds on any of the controllers After initializing the setting repeat the instructions from the 4 5 1 In...

Page 51: ...tering Lock Mode To prevent accidental pressing of the buttons and to prevent children from adjusting the controller you can activate the Temperature Lock Mode To activate or deactivate Lock Mode pres...

Page 52: ...n time by pressing the Up or Down button or 4 Press the OK button to save the timer setting Repeat these procedures for Reservation Schedule Settings 2 and 3 4 Press the OK button to finish and save t...

Page 53: ...is applied to A models with the preheating function only 4 9 Starting Recirculation Press the Preheat Timer button to start recirculation immediately regardless of the reservation schedule HEAT appea...

Page 54: ...ions shown here are only examples The setup you choose will vary based on the installation location local building codes and other factors Follow all applicable regulations when installing a cascade s...

Page 55: ...ion setup on the Main water heater press and hold the Diagnostic and Reset buttons for more than 5 seconds The water heater will revert to independent operation Repeat steps 1 3 to reassign the Main w...

Page 56: ...55 Appendixes 6 1 Covering the Clamps with Front Cover Cap After installing the water heater completely cover the indicated clamps with the front cover caps provided with the product 6 Appendixes...

Page 57: ...ater Flow GPM NPN 120E 0 5 10 15 20 25 30 35 40 45 50 Pressure Loss Psi 0 1 2 3 4 5 6 7 8 9 10 11 Water Flow GPM NPN 160U 160E 0 5 10 15 20 25 30 35 40 45 50 Pressure Loss Psi 0 1 2 3 4 5 6 7 8 9 10 1...

Page 58: ...14pin CON10 Modulating GV 1 1 15 CON1 APS Flow sensor DHW Inlet1 Temp Sensor DHW Outlet2 Temp Sensor DHW Outlet1 Temp Sensor Antifreeze Temp Sensor GROUND P E 1 PIN2 M MIXING V V 1 CON5 1 CON3 M WAV...

Page 59: ...Relay 7 Driving Circuit Flow Sensor APS DC 12 V Fan Hall Sensor FAN Water Adjustment Valve Flow Control DC 15 V Water Leakage Detection Outlet Thermistor 1 Outlet Thermistor 2 Inlet Thermistor 1 Modul...

Page 60: ...59 Appendixes 6 5 Component Assembly Diagrams and Parts Lists 6 5 1 Case Assembly NPN 160U 180U 199U 12 10 8 10 7 12 6 3 4 2 1 20 9 5 11 13 19 21 18 17 15 14 16 2 6 16 22...

Page 61: ...haust Switch 30022669A 30024038 8 Rubber Ring 20006973 9 20025127 10 20029318 11 Junction Box 20046065 12 Front Cover Bracket 20024042 13 External Base Toggle Latch 20007514 14 Gas Control Valve 30022...

Page 62: ...61 Appendixes 6 5 2 Case Assembly NPN 120E 160E 180E 199E 7 2 1 15 4 16 6 5 14 8 13 3 10 9 12 11 7 11 18 2 5 17...

Page 63: ...t Cover Bracket 20024042 8 External Base Toggle Latch 20007514 9 Gas Control Valve 30022125A 30022700 10 Air Pressure Sensor 30010238B 30010238 11 Pipe Clip 20045992A 20045992 12 Front Panel 30022765B...

Page 64: ...t Part Remark 1 Chamber Case 30023298A 30023298 160U 30023299A 30023299 180U 199U 2 Pressure Test Nipple 20048333 3 Gasket 20047192A 20047192 4 20048027 5 Heat Exchanger 30022984A 30022984 160U 300227...

Page 65: ...mber Cover 30022897A 30022897 160U 30022675A 30022675 180U 199U 18 Gasket 20046301A 20046301 160U 20045931A 20045931 180U 199U 19 20046302A 20046302 160U 20045932A 20045932 180U 199U 20 20045933A 2004...

Page 66: ...ription Service Part Part Remark 1 Chamber Case 30025500A 30025500 120E 30023298A 30023298 160E 30023299A 30023299 180E 199E 2 Pressure Test Nipple 20048333 3 Gasket 20047192A 20047192 4 20048027 5 He...

Page 67: ...505 120E 30022896A 30022896 160E 30022679A 30022679 180E 199E 14 Chamber Cover 30025506A 30025506 120E 30022903A 30022903 160E 30022831A 30022831 180E 199E 15 Gasket 20050740A 20050740 120E 20047856A...

Page 68: ...tor 30022787A 30022787 25 Gas Manifold 30025510A 20050749 120E 30022899A 20046303 160E 30022704A 20045981 180E 199E 26 Gas Stage Valve Body 30025510A 20050748 120E 30022899A 20046306 160E 30022704A 20...

Page 69: ...68 Appendixes 6 5 5 Water Assembly 1 5 12 13 14 15 16 7 6 8 8 8 4 2 3 8 8 11 10 9...

Page 70: ...199 6 Outlet Pipe 30022891A 30022891 120 160 30022712A 30022712 180 199 7 Mixing Pipe 30022892A 30022892 120 160 30022713A 30022713 180 199 8 Pipe Clip 20045992A 20045992 9 Hot Water Supply Adapter 30...

Page 71: ...dirt corrosive elements and flammable vapors Is the water heater and vent piping clear of combustible materials including clothing cleaning materials and rags Connecting the Gas Supply Yes No Does th...

Page 72: ...ve you properly sealed all air intake and exhaust joints from the flue collar to the to the vent termination Have you installed an end cap on the vent pipe Have you checked the venting for leaks Is th...

Page 73: ...to the system 6 7 1 Basic Principles The following diagram shows the basic operation of the heater system with the Navien H2Air add on controller CAUTION Do not configure the system for DHW recircula...

Page 74: ...e is a demand for hot water 6 8 1 Basic Principles The following diagram shows the basic operation of the water heater system with the Navien HotButton kit CAUTION The Navien HotButton can be used ONL...

Page 75: ...fied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS No installation or replacement of a vented gas appliance shall be permitted unless a battery powered or electrically hard wired carbon monoxide detecto...

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