Navien NPE-180A Installation Manual
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Navien NPE-180A Installation Manual

Condensing water heater
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Installation
Manual
Getting Service
If your water heater requires service, you have several options for getting service:
Contact Technical Support at 1-800-519-8794 or on the website: www.navien.com.
For warranty service, always contact Technical Support first.
Contact the technician or professional who installed your water heater.
Contact a licensed professional for the affected system (for example, a plumber or electrician).
When you contact Technical Support, please have the following information at hand:
Model number
Serial number
Date purchased
Installation location and type
Error code, if any appears on the front panel display.
Condensing Water Heater
Navien, Inc.
20 Goodyear lrvine, CA 92618 TEL 1-800-519-8794 FAX +949-420-0430 www.navien.com
Version: 4.1 (Jan. 08, 2015)

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Summary of Contents for Navien NPE-180A

  • Page 1 Getting Service If your water heater requires service, you have several options for getting service: Contact Technical Support at 1-800-519-8794 or on the website: www.navien.com. For warranty service, always contact Technical Support first. Contact the technician or professional who installed your water heater.

  • Page 2: Installation Manual

    Condensing Water Heater Installation Manual Model NPE-180A/ 210A/ 240A NPE-180S/ 210S/ 240S * Lead Free Keep this manual near this water heater for future reference whenever maintenance or service is required. Certified for installation in a manufactured (mobile) home. * The wetted surface of this product contacted by consumable water contains less than one quarter of one percent(0.25%) of lead by weight.

  • Page 3: Table Of Contents

    5. Appendixes 5.1 Gas Conversion 5.2 Technical Data 5.3 Wiring Diagram 5.4 Ladder Diagram 5.5 Component Assembly Diagrams and Parts Lists 5.6 Installation Check list 5.7 Navien ComfortAir+ Add-on Controller Kit (Optional) 5.8 Requirements for the State of Massachusetts Contents...

  • Page 4: Safety Information

    1. Safety Information The following safety symbols are used in this manual. Read and follow all safety instructions in this manual precisely to avoid DANGER unsafe operating conditions, fire, explosion, property damage, personal injury, or death. DANGER Indicates an imminently hazardous situation which, if not avoided, could result in severe injury or death.
  • Page 5 CAUTION WARNING Do not turn on the water heater unless the water and gas supplies are fully opened. Doing so may damage the water heater. Do not turn on the water if the cold water supply shut- off valve is closed. Doing so may damage the water heater.

  • Page 6: About The Water Heater

    Tapping Screws & Anchors Ready-Link Outdoor Vent Kit 2” Vent Termination Caps 2” Wall Flanges Communication Cable 3” Vent Termination Caps 3” Wall Flanges Conversion Kit Spare Parts External Pump Connector Navien Comfort Air+ (<150W,1.5A) Add-on Controller Kit About the Water Heater...

  • Page 7: Specifications

    2.3 Specifications The following table lists the specifications for the water heater. Additional specifications about water, gas, electric, and air supplies (venting) appear in the Installation section. Item NPE-180(A) NPE-180 NPE-210(A) NPE-210 NPE-240(A) NPE-240 Natural Gas 15,000-150,000 BTU/H 19,900-180,000 BTU/H 19,900-199,900 BTU/H Heat Capacity (Input)

  • Page 8: The Front Panel

    2.4 The Front Panel The front panel allows you to adjust the water temperature and view the operating status or error codes. Remove the protective sheet from the front panel before using it. Error Master Unit A code will appear on the display Cascade operation Hot Water Recirculation Display...

  • Page 9: Components

    Front Panel Circulation Pump Condensate Trap Gas Valve PCB Box Water Adjustment Valve 2-Way Valve Gas Inlet Fitting Water Inlet Filter Condensate Drain Fitting DHW Supply Fitting Condensate Drain Lid Recirculation Inlet Fitting [NPE-180A/ 210A/ 240A] About the Water Heater...
  • Page 10 Exhaust Duct Exhaust Limit Temperature Sensor Intake Air Duct Exhaust Body Fan Motor Ignition Transformer Burner Dual Venturi Primary Heat Exchanger Gas Pipe Secondary Heat Exchanger APS (Air Pressure Sensor) Freeze Protection Switch Front Panel Condensate Trap Gas Valve PCB Box Flow Sensor Water Adjustment Valve Mixing Valve...

  • Page 11: Dimensions

    Hot Water Outlet 3/4" Recirculation Inlet 3/4" Cold Water Inlet 3/4" Gas Inlet 3/4" Condensate Outlet 1/2" Overhead View Supply Connections 1.5" (38mm) 14.3" (364mm) 4.5"(115mm) 6.7"(170mm) 2.3" 3.0" 8.3" (60mm) (77mm) (212mm) 17.3" (440mm) [NPE-180A/ 210A/ 240A] About the Water Heater...
  • Page 12 Supply Connections Description Diameter Air Intake 2" Exhaust Gas Vent 2" Hot Water Outlet 3/4" Cold Water Inlet 3/4" Gas Inlet 3/4" Condensate Outlet 1/2" Overhead View Supply Connections 1.5" (38mm) 14.3" (364mm) 4.5"(115mm) 6.7"(170mm) 2.3" 11.3" (60mm) (289mm) 17.3" (440mm) [NPE-180S/ 210S/ 240S] About the Water Heater...

  • Page 13: Rating Plate

    à des altitudes de 0 à 4,500 pieds (1,370 m) conformément aux toutes les procédures d’installation à haute altitude CAN/CGA 2.17 à une pression normale. Pour les installations à élévations en haut de 4,500 pieds, appeler le bureau de Navien.

  • Page 14: Installing The Water Heater

    Installing the water heater in a location without a drain gas, water, and electrical supplies. Carefully consider the following will void the warranty and Navien will not be responsible for factors when choosing an installation location: water damages that occur as a result. For more information about condensate drainage, refer to “3.5 Connecting the Condensate...

  • Page 15: Mounting The Water Heater To The Wall

    3.2 Mounting the Water Heater to the Wall Install the water heater in an area that allows for service and Navien water heaters come with an upper mounting bracket that is maintenance access to utility connections, piping, filters, and traps.

  • Page 16: Connecting The Gas Supply

    Do not attempt a field conversion of this water heater Gas Inlet Adapter without a Navien gas conversion kit. Doing so will result in dangerous operating conditions and will void the warranty. Navien recommends connecting the water heater as the first water heater downstream of the gas meter, to ensure a sufficient gas supply.
  • Page 17 Full size When using rigid pipe, Navien recommends the Gas Pipe installation of a union on the gas supply line close to the water heater, to facilitate any future...
  • Page 18 3.3.1 Gas Pipe Sizing Tables (Referenced from 2012 National Fuel Gas Code) These tables are for reference only. Please consult the gas pipe manufacturer for actual pipe capacities. Maximum Natural Gas Delivery Capacity in Cubic Feet (ft ) per Hour (0.60 Specific Gravity; 0.5" WC Pressure Drop). Contact your gas supplier for BTU/ft3 ratings. Use 1,000 BTU/ft3 for simplified calculations.
  • Page 19 Maximum Liquefied Propane Delivery Capacity in Thousands of BTU/H (0.5" WC Pressure Drop) Length (including fittings) Pipe Size 100' 125' 150' 175' 200' 250' (3m) (6m) (9m) (12m) (15m) (18m) (24m) (30m) (38m) (45m) (53m) (60m) (76m) 1/2" 3/4" 1" 1,150 1 1/4"...

  • Page 20: Connecting The Water Supply

    2. Open a hot water faucet. The water heater should turn on and 8. When the water heater reaches its maximum firing rate, check the gas in the gas supply line will be purged. the inlet gas pressure reading on the manometer. The gas pressure must fall within the ranges specified on page 18.
  • Page 21 The following is a typical water piping example for NPE-180A/ 3.4.1 Using the Water Heater for Combination 210A/ 240A models. Water Heating and Space Heating When using the water heater for both water (potable) heating and space heating, follow these guidelines: Ensure that all piping and components connected the water heater are suitable for potable water applications.
  • Page 22 External Recirculation Mode To use the external recirculation mode: 1. Connect the water supply to support recirculation. Refer to the "[NPE-180A/ 210A/ 240A]" diagram on page 20. 2. Set the 2-way valve inside the water heater to “EXT. “ CAUTION Do not remove recirculation cap.
  • Page 23 3. Set the front panel DIP switches at the far left (set of ten) to: 3.4.3 External Pump Wire Connection 1—OFF; 2—ON. An external pump may be connected to the water heater for recirculation applications. When selecting a circulator, it shall be sized to maintain a flow of 2-4 GPM through the water heater.
  • Page 24 3. Remove the 2 screws holding the PCB box in place and remove 8. Locate the 10-switch DIP(SW1) on the front panel and turn on the PCB box from the system. the proper switches based on the desired recirculation setting (see Recirculation Dipswitch Settings below). Remove Screws here.
  • Page 25 Hot Water Pressure relief valve Domestic Recirculation Return Recirculation Using Two Pumps (Navien Internal Pump & External Pump) Shut-off Valve Hot water Cold water 3.4.4 Connecting a Pressure Relief Valve When installing the valve, follow these guidelines: WARNING Ensure that the discharge capacity of the pressure relief valve...

  • Page 26: Connecting The Condensate Drain

    3.5 Connecting the Condensate Drain b. From the water heater, through a neutralizing agent, and then The Navien Condensing Water Heater creates condensation when into an external drain. it operates. This condensation has an acidic pH of 3-5. Follow all...
  • Page 27 Do not connect more than one appliance to the neutralizer. If option 'b' is selected for condensate disposal, the Navien condensate neutralizer kit is recommended. The condensate from Figure 1. Horizontal installation the appliance flows through the neutralizing media and increases the pH of the condensate.

  • Page 28: Venting The Water Heater

    If you Navien also recommends installing a new vent system with this must install the water heater in an area with contaminated air, appliance. If reusing an existing vent system, thoroughly inspect use direct venting to supply air from outside the building.
  • Page 29 Description Canadian Direct Vent Installations US Direct Vent Installations Clearance above grade, veranda, porch, deck, or balcony 12 in (30 cm) 12 in (30 cm) Clearance to window or door that may be opened 36 in (91 cm) 12 in (30 cm) Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61 cm)
  • Page 30 4" (H) or 5" (H) or 5" (H) or will not be covered by the Navien warranty. If there is any question area of 1 in , per 7" round 8" round 8" round...
  • Page 31 Canadian Non-Direct Vent US Non-Direct Vent Description Installations Installations Clearance above grade, veranda, porch, deck, or balcony 12 in (30 cm) 12 in (30 cm) 48 in (120 cm) below or to side Clearance to window or door that may be opened 36 in (91 cm) of opening;...
  • Page 32 This water heater has a built-in control to limit the exhaust pages 32-33, count this as 5 linear feet (1.5m) temperature to 149°F (65°C). As a result, the Navien water of vent. heater can be vented with Schedule 40 PVC. If the incoming...
  • Page 33 3.6.4 Terminating the Vent Non-concentric Sidewall Venting – Air is drawn from a different location at a minimum of 12" (300mm) from the exhaust Before installing the water heater, determine what type of vent termination. Try to minimize the length of the intake air pipe termination is appropriate for the installation location and with this venting.
  • Page 34 Combustion Air Vent When installing a water heater outdoors, follow these guidelines: The Navien Outdoor Vent Kit must be used to ensure proper operation of the water heater. Ensure that there is plenty of clearance around the air intake and that it is adequately protected to prevent any debris, liquids, or flammable gases from entering the air intake.

  • Page 35: Connecting The Power Supply

    3.7 Connecting the Power Supply 3.8 Setting the DIP Switches The water heater has two DIP switch locations: on the main circuit board (PCB) and on the front panel. Each location has two sets WARNING of DIP switches that control the functionality of the water heater. Set the DIP switches appropriately, based on the installation Improperly connecting the power supply can result in electrical environment.
  • Page 36 Remark No Recirculation 1-OFF; 2-OFF; 3-OFF * Intelligent Preheating: Recirculation Mode- Learns the user's hot water Internal Recirculation 1-ON; 2-OFF; 3-OFF Internal Navien usage patterns and starts Pump ("A" model preheating prior to an External Recirculation 1-OFF; 2-ON; 3-OFF only) anticipated draw.

  • Page 37: Installing A Cascading System

    DHW Supply Line Cold Water Supply Line Recirculation Line [NPE-180A/ 210A/ 240A] The recommended minimum recirculation flow rate for each water heater is 2 GPM. Depending on the number of water heaters Note and the diameter of the recirculation line, it may not be necessary to connect all water heaters to the recirculation line. If this is the case, set the unconnected water heaters to internal recirculation mode.

  • Page 38: Connecting The Communication Cables

    4.2 Connecting the Communication Cables When plumbing a cascading system, consider the following pipe Up to 16 water heaters can be connected with Navien Ready-Link diameters and flow rates. Note that flow rates above 6.6 ft/s may communication cables. Select one of the water heaters in the cause pipe erosion.
  • Page 39 2. On the slave water heater, press and hold the Diagnostic and Down(-) buttons for more than 2 seconds. “SL.01” will appear on the display to confirm that this water heater is set as a slave. 3. Repeat step 2 to configure the rest of the slave water heaters in the system.

  • Page 40: Appendixes

    WARNING This conversion kit shall be installed by a qualified service agency* in accordance with Navien’s instructions and all applicable codes and requirements of the authority having jurisdiction. The information in these instructions must be followed to minimize the risk of fire or explosion or to prevent property damage, personal injury or death.
  • Page 41 Figure 3. Detaching Gas Valve from could result in damage to the valve, causing potential severe Gas Inlet Pipe and Fan Motor Assembly personal injury, death or substantial property damage. Navien water heaters are shipped ready to fire natural gas ONLY. Appendixes...
  • Page 42 7. Replace the old Orifice piece with the new part for use with LP gas. Ensure that the Orifice is properly seated inside the port before proceeding to the next step. 8. Replace the gas inlet pipe to its original position and use all screws to secure all connections.
  • Page 43 The set screw is located behind the screw-on Note Fuel Heater cover. This must be removed first. d. Fully open several hot water fixtures and set the water NPE-180A heater to operate at 2-stage MAX mode (refer to NPE-180S 10.2 10.8 value at high fire.
  • Page 44 Connect a manometer to the offset pressure port. For dual port manometers, use the positive pressure side. Model Kit Part No. Gas Type Offset Figure 10 NAC-01 -0.03"±0.01" NPE-180A NPE-180S The set screw is located behind the screw-on Note NAC-100 -0.04"±0.01" cover. This must be removed first. NAC-02 -0.02"±0.01"...
  • Page 45 5.1.1 Setting the Operation Mode 1. Using the Front Panel, press and hold the Diagnostics Button for over 5 seconds until “1.TST” is displayed. 2. Press the + (Up) button once to change the display to “2.OPR”. 3. Press the Information Button once to acess the Operation Mode menu.

  • Page 46: Technical Data

    5.2 Technical Data Pressure Drop Curve [NPE-240A/ 240S] [NPE-210A/ 210S] [NPE-180A/ 180S] Appendixes...
  • Page 47 Outlet Flow Data [NPE-240A] [NPE-210A] [NPE-180A] At altitudes above 2,000 ft (610m), the outlet flow will be reduced by 4% for each 1,000 ft (305 m) of altitude gain. Note Appendixes...
  • Page 48 Outlet Flow Data [NPE-240S] [NPE-210S] [NPE-180S] At altitudes above 2,000 ft (610m), the outlet flow will be reduced by 4% for each 1,000 ft (305 m) of altitude gain. Note Appendixes...

  • Page 49: Wiring Diagram

    5.3 Wiring Diagram [NPE-180A/ 210A/ 240A] Appendixes...
  • Page 50 [NPE-180S/ 210S/ 240S] Appendixes...

  • Page 51: Ladder Diagram

    Relay 3 Outlet MCU 1 MGV1 MCU 2 Thermistor 2 MGV2 Inlet Relay 1 Thermistor 1 Relay 2 Inlet Relay 4 Thermistor 2 Exhaust Thermistor Communication Interface UART FRONT Communication PANEL Interface Ready Link Ready Link Interface [NPE-180A/ 210A/ 240A] Appendixes...
  • Page 52 NEUTRAL EXT_PUMP Relay 1 FILTER VENTURI Relay 2 Relay 3 IGNITER Relay 4 PUMP Primary Primary SMPS Speed Control DC15V Secondary DC24V DC12V 200V FSA Power DC5V Switch Water Mixing Water Adjust Valve Valve Flame Rod Flow Sensor H.T.L WD-PSS Hall Sensor Outlet Driving Circuit...

  • Page 53: Component Assembly Diagrams And Parts Lists

    5.5 Component Assembly Diagrams and Parts Lists 5.5.1 Case Assembly Appendixes...
  • Page 54 Description Part # Remark Intake Air Duct Assembly 30008662B Intake Air Filter 20007667A 20019078C NPE-180A/210A/240A Case 20026559B NPE-180S/210S/240S Air Pressure Sensor 30010346A Panel Bracket 20018388A 30008678B NPE-180A/210A/240A Cover 30011694A NPE-180S/210S/240S Case Lower Bracket 20007643B 30011969A Power Switch 30009482A Front Panel...
  • Page 55 5.5.2 Burner Assembly(NPE-180A/ 210A/ 240A) 17-1 11-1 Appendixes...
  • Page 56 Description Part # Remark 20018362A NPE-180A Heat Exchanger Assembly 30008780A NPE-210A/240A Fan Packing 20022744A Fan Bracket(F) 20022095A Flow Sensor Assembly 30008571A Thermistor 30008366A Fan Braket(R) 20022096A 30009166A NPE-180A Cold Inlet Pipe 30008446A NPE-210A/240A O-Ring (Φ17.5x2.7t) 20006947A WPA-A (Clip) 20018344A Thermistor...
  • Page 57 5.5.3 Burner Assembly(NPE-180S/ 210S/ 240S) 10 4 10 5 Appendixes...
  • Page 58 Description Part # Remark Ignition Transformer 30010455A Fan Bracket (R ) 20022096A Thermistor 30009478A Exhaust 30011706A NPE-180S Heat Exchanger Assembly 30011705A NPE-210S 30011704A NPE-240S Ignitor 30012226A Packing (Φ26.5x2.4t) 20006868A 30011519A NPE-180S Heat Exchanger Outlet Pipe 30011515A NPE-210S/240S WPA-C (Screw) 20026780A Fastner 20017726A O-Ring (Φ17.5x2.7t)
  • Page 59 5.5.4 Waterway Assembly(NPE-180A/210A/240A) 12-5 12-4 12-2 12-3 12-1 Description Part # Remark Buffer Tank 30010953A Hot Water Outlet Pipe Assembly 30008338A Pipe Adapter 30008349A O-RING (P20) 20017212A Thermistor (Red) 30008366A O-RING (P16) 20006947A Pipe Clip 20007733A Return Pipe Assembly 30008350A...
  • Page 60 Description Part # Remark O-RING (P20) 20017212A O-RING (P19) 20017211A Water Filter 30008351A Pipe Clip 20007733A Circulation Pump 30010346A Pump Air Seperator 30006831A Drain Plug 30003550B O-RING (P18) 20006947A Fastner 20017726A Water adjustment valve (WAV) 30008245A WAV Outlet Pipe Assembly 30008624A O-Ring (P16) 20011438A...
  • Page 61 5.5.5 Waterway Assembly(NPE-180S/ 210S/ 240S) Appendixes...
  • Page 62 Description Part # Remark Bracket 20026489A Thermistor 30008366A Water Filter 30008171A Cold Water Inlet Adapter 30011597A O-Ring (P15) 20017217A Fastner 20007859A Flow Sensor 30011534A O-Ring (P16) 20017210A Flow Sensor Outlet Adapter 20025959A Outlet Adapter 20025961A Fastner 20017726A Water Adjustment Valve (WAV) 30011532A Inlet Adapter 20025962A...
  • Page 63 5.5.6 Fan(Gas) Assembly Appendixes...
  • Page 64 Description Part # Remark 30009921A NPE-180S/180A Gas Adapter 30009922A NPE-210S/210A/240S/240A 30013323A NPE180S/180A Gas Pipe 30008431A NPE-210S/210A/240S/240A Gas Connector 20018430A Gas Valve 30008429A Gas Inlet Adapter 20023809A Fan Assembly 30008834A 30009219A NPE-180S/180A Dual Venturi 30008909A NPE-210S/210A/240S/240A 20019142A NPE-180S/180A Silence 20023829A NPE-210S/210A/240S/240A 20023861A NPE-180S/180A Silence Adapter...

  • Page 65: Installation Check List

    Owner’s Manual. If you have additional questions or need assistance with installation, contact Technical Support at 1-800-519-8794 or 1-949-420-0420, or refer to the technical support section of Navien’s website (www.navien.com). Installing the Water Heater Have you maintained the required clearances from building openings and intake air vents?
  • Page 66 Connecting a Pressure Relief Valve Have you installed the pressure relief valve on the hot water outlet pipe near the water heater? Have you installed a discharge drain tube from the pressure relief valve to within 6-12" (150-300mm) of the floor? Connecting the Condensate Drain Have you installed a condensate drain line from the water heater to a drain or laundry tub? Venting the Water Heater...

  • Page 67: Navien Comfortair+ Add-On Controller Kit (Optional)

    This device is designed to work with NPE-180A and 240A models ONLY. Basic Principles The following diagram shows the basic operation of an NPE-180A/240A water heater system with the ComfortAir+ add-on controller. CAUTION Do not configure the system for DHW recirculation when it is configured to run an air hanler using the ComfortAir+ add-on controller. DHW recirculation and Navien ComfortAir+ configurations cannot be used at the same time.

  • Page 68: Requirements For The State Of Massachusetts

    5.8 Requirements for the State of Massachusetts NOTICE BEFORE INSTALLATION This appliance must be installed by a licensed plumber or gas fitter in accordance with the Massachusetts Plumbing and Fuel Gas Code 248 CMR Sections 2.00 and 5.00. IMPORTANT: In the State of Massachusetts (248 CMR 4.00 & 5.00) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall...
  • Page 69 Memo...

This manual is also suitable for:

Npe-240aNpe-210a

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