Navien NCB-150E Service Manual
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Navien NCB-150E Service Manual

Ncb-e condensing water heaters
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See also: Operation & Installation Manual
Service Manual
NCB-E Condensing Combi Boiler
Getting Service
If your boiler requires service, you have several options for getting service:
Contact Technical Support at 1-800-519-8794 or on the website: www.navienamerica.com.
●
For warranty service, always contact Technical Support first.
Contact the technician or professional who installed your boiler.
●
Contact a licensed professional for the affected system (for example, a plumber or electrician).
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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.
●
Navien, Inc.
800.519.8794
www.Navien.com
20 Goodyear lrvine, CA 92618
T H E
L E A D E R
I N
C O N D E N S I N G
Version: 1.4 (Oct 26, 2015)
T E C H N O L O G Y

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July 29, 2025

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Summary of Contents for Navien NCB-150E

  • Page 1 ● Installation location and type ● Error code, if any appears on the front panel display. ● Version: 1.4 (Oct 26, 2015) Navien, Inc. 800.519.8794 www.Navien.com 20 Goodyear lrvine, CA 92618 T H E L E A D E R...
  • Page 2 Service Manual NCB-E Condensing Water Heaters Model NCB-150E NCB-180E NCB-210E NCB-240E Keep this manual near this boiler for future reference whenever maintenance or service is required. NSF/ANSI 372 * 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 4 1.00 First Issue October/27/2013 1.10 Cascade information addition January/03/2014 1.20 E001 information addition, E205 information revision June/12/2014 1.30 AFUE Change November/24/2014 1.40 NCB-150E,180E,210E and 240E Model Added September/30/2015 1.10 Reviewed BY : 1.20 Reviewed BY : Paek Ji Ho Revisions...

  • Page 5: Table Of Contents

    Contents 1. Safety Information 4.9 Key Components Description 4.9.1 PCB 1.1 Safety Definitions 4.9.2 High Limit Switch 1.2 Safety Symbols 4.9.3 Thermistor 1.3 Symbols Used in the Instructions 4.9.4 Fan Motor 4.9.5 Flame Rod Assembly 1.4 Safety Precautions 4.9.6 Ignition Transformer 2.
  • Page 6 6. Replacement of Parts 6.1 Replacement Procedure 6.2 Components Replacement Instructions 6.2.1 PCB 6.2.2 Fuse 6.2.3 Fan Motor (Combustion Air) 6.2.4 Flame Rod 6.2.5 Ignition Transformer 6.2.6 APS 6.2.7 Main Gas Valve 6.2.8 Condensate Trap 6.2.9 Flow Sensor 6.2.10 Circulation Pump 6.2.11 3-way Valve 6.2.12 Water Pressure Sensor 6.2.13 Space Heating Strainer...

  • Page 7: Requirements For The State Of Massachusetts

    Requirements for the State of Massachusetts 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 8: Navien Warranty

    Warranty Period Warranty Exclusions Navien products come with a limited warranty covering labor, Navien’s Limited Warranty shall be void in the event of an parts and the heat exchanger. The following warranty periods occurrence of any of the following: begin to run from the date of original installation. The date of Improper installation, failure to install in strict compliance with ●...
  • Page 9 Installation procedures at normal manifold pressure. For installation instructions at altitudes higher than 4,500 ft, please contact Navien. *Cet appareil est certifié pour une utilisation à des altitudes de 0 à 4,500 pieds (1,370 m) conformément aux toutes les procédures d’installation à...
  • Page 10 Abbreviations and Definitions Abbreviation Definition NCB-E General name of NCB-180E, NCB-210E, and NCB-240E Natural Gas Propane Gas Air Pressure Air Pressure Sensor Domestic Hot Water Fan Motor GARC Gas Air Ratio Control Gallons Per Minute Main Gas Valve Revolutions Per Minute Printed Circuit Board Electromagnetic Interface High Temperature Limiter...

  • Page 11: Safety Information

    1. Safety Information 1.1 Safety Definitions 1.4 Safety Precautions The following safety symbols are used in this manual. Read and follow all safety instructions in this manual precisely to avoid unsafe DANGER operating conditions, fire, explosion, property damage, personal injury, or death. FLAMMABLE MATERIALS Keep the area around the boiler clear and free from flammable materials.
  • Page 12 DANGER DANGER COMPROMISED VENTING SYSTEM Failure to follow the Venting Section of the installation ● manual may result in unsafe operation of this boiler. To avoid the risk of fire, explosion or asphyxiation from carbon monoxide, never operate the boiler unless it is properly vented to the outside and has an adequate air supply for proper operation.
  • Page 13 DO NOT attempt to change the water temperature while ● Navien America Inc. is not liable for any property damage someone is using the boiler. and/or personal injury resulting from unauthorized DO NOT use parts other than those specified for this ●...
  • Page 14 CAUTION WARNING Do not attempt to repair or replace any part of the boiler, ● unless it is specifically recommended in this manual. For all other service, contact an authorized technician or licensed professional. Improper adjustments, alterations, service, or maintenance may lead to property damage, personal injury, or death and will void your warranty.

  • Page 15: Product Information

    2. Product Information 2.1 Product Information Navien features the NCB-E series gas boiler with a built-in Circulation Pump and Air vent. This appliance is fully modulating and provides central heating and domestic hot water. Depending on the heat capacity, each model is divided into three types; 150E, 210E and 240E.

  • Page 16: Components

    2.2 Components The following diagram shows the key components of the boiler. Component assembly diagrams and particular parts lists are included in the Appendixes. Intake Air Exhaust Air Filter Flue Duct Mixing Chamber Igniter & Flame Rod Condensate Trap Front Panel Auto Feeder (Make-up water) Power Switch...
  • Page 17 Pressure Relief Valve Adapter Fan & Motor Dual Venturi Ignition Transformer High Limit Switch Premix Burner Primary Heat Exchanger Air Pipe Secondary Heat Exchanger Gas Pipe Pressure Sensor (LWCO) Air Vent Gas Valve Circulation Pump Flow Sensor 3-Way Valve DHW Inlet Filter (with built-in flow restrictor) Space Heating Supply...

  • Page 18: Technical Data

    2. Based on U.S. Department of Energy (DOE) test procedures. 3. The net AHRI water ratings shown are based on a piping and pickup allowance of 1.15. Consult Navien before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping system, etc.
  • Page 19 General Specifications Item NCB-150E NCB-180E NCB-210E NCB-240E Dimensions 17 in (W) x 28 in (H) x 12 in (D) Weight 66 lbs (30 kg) 74 lbs (34 kg) 84 lbs (38 kg) 84 lbs (38 kg) Installation Type Indoor Wall-Hung...

  • Page 20: Dimensions

    3.2 Dimensions The following diagrams show the dimensions of the boiler and the table lists the supply connections. Supply Connections Description Diameter Pressure Relief Valve Adapter Air Intake 2 in Exhaust Gas Vent 2 in Space Heating Supply 1 in Space Heating Return 1 in Hot Water Outlet (DHW)

  • Page 21: System Details

    Reserved The boiler has two DIP switch locations: on the main circuit board (PCB) and on the front panel. Each location has two sets of DIP NCB-150E 5-ON, 6-ON switches that control the functionality of the boiler. Set the DIP...
  • Page 22 Setting the Front Panel DIP Switches Set of DIP Switches 1 (Set of 10) ● The DIP SW 1 on the front panel configures the temperature unit, well pump, and high altitude settings. SW1 NO. Application Setting Remarks Reserve °C (Celsius) 2-ON Temperature Unit °F (Fahrenheit)

  • Page 23: Measuring The Inlet Gas Pressure

    4.2 Measuring the Inlet Gas Pressure To measure the inlet gas pressure: 1. Shut off the manual gas valve on the gas supply line. WARNING The boiler cannot function properly without sufficient inlet gas pressure. Measuring the inlet gas pressure should be performed by a licensed professional only.
  • Page 24 5. Loosen the screws indicated in the figure below and connect a manometer to the pressure port. Reset the manometer to zero NOTE before use. For NCB series, remove the boiler front cover by loosening the 4 Phillips head screws securing it to the case.

  • Page 25: Gas Pipe Sizing Tables (Referenced From 2012 National Fuel Gas Code)

    4.2.1 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/ft ratings.
  • Page 26 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 27: Gas Conversion

    1 for illustration of the front cover on the unit. 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 28 6. Loosen the three screws indicated in the figure. 8. With the internal components exposed, locate the gas inlet pipe and the gas valve in the middle of the unit, as shown in Figure 2. Gas Inlet Pipe Gas Valve Figure 2.
  • Page 29 Attempting to alter or measure the gas valve outlet pressure ● could result in damage to the valve, causing potential severe personal injury, death or substantial property damage. Navien NCB-E boilers are shipped ready to fire natural gas Figure 5. Exploded View of Gas Pipe Assembly ONLY. DANGER See Figure 5.
  • Page 30 12. Remove the Gas Orifice, ensure that the packing is properly seated inside the port, and then install the new Gas Orifice for use with LP gas. Ensure that the Orifice is properly seated on the packing inside the port before proceeding to the next step. Packing DANGER 13.
  • Page 31 Model Fuel high fire. If the CO values do not match Table 2 at high fire, do not adjust the gas valve. Check for the proper Gas Orifice. NCB-150E 10.2 10.8 DANGER NCB-180E 10.2 10.8 Improper gas valve settings can cause severe personal injury, death or substantial property damage.
  • Page 32 c. Fully open a hot water fixture and set the boiler to operate at 1-stage MIN mode (refer to table 2). Measure the offset value at low fire and compare it to the values in Table 3. If the offset value is out of range, the gas valve set screw will need to be adjusted.

  • Page 33: The Front Panel

    4.4 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. 4.4.1 Icons and Digital Display The icons and digital display on the front panel provide important information required for the boiler’s operation.

  • Page 34: Buttons

    4.4.2 Buttons Using the buttons on the front panel, you can turn on or off the boiler, monitor the current operation status, and set the values required for the boiler’s operation, such as space heating and DHW supply temperatures. Refer to the following table for detailed information.
  • Page 35 Short Key Function Remark [Diagnostic] short key Display of information for service Converts () in order of Setting heating temperature Sets heating temperature/hot water temperature => Setting hot water temperature [Mode] short key Displays/confirms information for customers => Displaying customer information =>...

  • Page 36: Turning The Boiler On Or Off

    4.4.3 Turning the Boiler On or Off * When the power is first applied, please turn the panel segments and icons on for 3 seconds (in order to check LCD defect) * The firmware version of panel will be displayed for 2 seconds after 3 To turn the boiler on or off, press the [Power] button.
  • Page 37 Item Description Display method Item Description Display method When the current supply When the current supply water temperature is 120°F water temperature is 120°F and the water pressure is and its water pressure is 12.3psi, the image below 12.3psi, the image below repeats at 5 second intervals repeats at 5 seconds intervals.

  • Page 38: Error Display And Reset

    4.4.5 Error Display and RESET 4.4.6 Adjusting the Space Heating Temperature 1. When an error higher than Level 2 occurs (the Boiler may stop operation or only has basic functions), the Boiler enters <Error The boiler is set to 140°F (60°C) by default. To adjust the space Display mode>...

  • Page 39: Adjusting The Dhw Temperature

    3. You can adjust the temperature while the display is flashing. 3. Press + (Up) or – (Down) buttons until the desired temperature Once the display stops flashing, the temperature setting is appears on the display. stored. NOTE Take note of the original heating temperature in case you ●...

  • Page 40: Viewing Basic Information (For Homeowner)

    4.4.8 Viewing Basic Information (For Homeowner) To view information about the boiler, press the [Mode] button three times. “INFO” will appear in the display. Press the [+] or [–] buttons to switch between the information types. Item Description Display For Celsius (°C) mode; ex) at 60°C (A) Space heating supply Display of the current space heating water temperature...
  • Page 41 Item Description Display Using sensor GPM flow rate display ex) 10.2GPM Display of the current flow rate Minimum (E) Flow rate display unit (0.2 Gal/min or l/min) Outdoor Temperature display for Celsius (°C) mode with optional sensor, ex) at 15°C (F) Outdoor air temperature (with Display of current outdoor temperature...

  • Page 42: Error Occurrence History Display

    4.4.9 Error occurrence history display NOTE 1. At the <Normal operation mode> or <Error display mode>, press the [Info] button for over 2 seconds to access the error While in <ERROR HISTORY DISPLAY MODE> the first digit ● history mode. indicates the history of the error with 0 being the most The most recent error will be displayed first.

  • Page 43: Information Display (For Servicer)

    4.4.10 Information display (for servicer) 1. At the <Normal operation mode>, press the [Diagnostic] button once for 5 seconds to access the service information display. 2. Whenever the [+] / [-] button is pressed, the Information Data items are increased/decreased and displayed. 3.
  • Page 44 Item Description Display Using sensor GPM flow rate display Display of the current flow rate ex) 10.2GPM (E) Flow rate Minimum display unit (0.2 Gal/min or l/min) Outdoor Temperature display for Celsius (°C) mode with optional sensor, ex) at 15°C (F) Outdoor air temperature Display of current outdoor (with optional Outdoor...
  • Page 45 Item Description Display % Heat capacity display in percentage ex) 100%, Display of current heat capacity % (J) Heat Capacity range: 50-100% Default : 100% Displays the flame by flame detection AD value (0-255) , ex) 200 Display of flame detection current AD value (K) Flame State Flame ON : Below 70...
  • Page 46 Item Description Display Exhaust Gas Temperature display for Celsius (°C) mode with sensor, ex) 60°C Exhaust Gas Temperature display for Fahrenheit (°F) mode with sensor, Current exhaust gas temperature ex) 120°F (P) Exhaust Gas Temperature display Exhaust Gas Temperature display without sensor ex) Capacity 180, condensing for the American market ex) Capacity level 240, for the Korean market Currently set model and capacity...
  • Page 47 Item Description Display 0-2,000ft 2,000-5,400ft (S) Altitude setting Display of current altitude level information setting 5,400-7,700ft 7,700-10,100ft CASCADE OFF (T) Current units in cascade Display of current number of system. cascade unit. CASCADE ON CASCADE OFF CASCADE ON & CASCADE UNIT Operation ON (U)Cascade Operation Display of current cascade Information...

  • Page 48: Special Parameter Mode

    4.4.11 Special Parameter mode You can modify parameter settings for boiler operations, such as the space heating and DHW temperature ranges, in different operating conditions. Follow the instructions below to access the Special Parameter mode and change the available settings. CAUTION Parameters must be set by a qualified professional with an extensive understanding of the boiler system.
  • Page 49 CAUTION If you enter an incorrect password 10 times or make no input 5 minutes, the boiler will return to the Normal Mode. ● To return to the previous mode, press the Reset button. ● The Factory default password is “1234” ●...
  • Page 50 Item Description Display For Celsius (°C) mode; ex) at - 10°C This mode is used to configure the lowest outdoor temperature. The boiler will operate at the high end of the supply or return set-point range at this outdoor temperature. For Fahrenheit (°F) mode;...
  • Page 51 Item Description Display This menu is used to configure the desired space heating capacity. When the MAX limited calorie for Space boiler operates in the Normal mode, the space heating capacity is limited to heating is 95% the set value (%) (F) Space Heating Max Heat Capacity Setting range...
  • Page 52 Item Description Display For Celsius (°C) mode; ex) at 0°C During space heating, the boiler turns off the burner when the space heating supply temperature meets or exceeds the burner-off temperature. (L) CH Burning OFF For Fahrenheit (°F) mode; ex) at Setting range Default Differential...
  • Page 53 Item Description Display For Celsius (°C) mode; ex) at 65°C This menu may be used to make changes to the maximum return temperature range the Return Control mode is in use. When configuring the Custom mode in the Outdoor Reset Control mode, the return temperature (P) Return Absolute changes based on the return absolute MAX temperature range.
  • Page 54 Item Description Display All the slave units are NPE water heaters. This menu may be used to set the communication protocol for the cascade (T) Cascade Protocol system. Set the parameter values according to the type of slave units installed Slave units consist of NR/NP water setting in the cascade system.
  • Page 55 Item Description Display This menu may be used to set a new password to access the parameter setting menu. To set a new password: 1. Move to [*.PSC] and press the “Mode” button. The current password is displayed, with the first digit flashing. 2.
  • Page 56 Component Test Performed Display Method The current APS value and the current RPM value are repeatedly displayed at intervals of 2 seconds. Gradually increase / decrease the speed of the fan motor starting from 0 RPM to full speed and back down to 0 RPM Displays On or Off according to pump status.
  • Page 57 (3) Operation conditions Settings 1. While in <Special Parameter mode>, press the [+] / [-] button and then press the [Mode] button once when “3. OPR” is displayed on the front panel. 2. Whenever the [+] / [-] button is pressed, it increases / decreases the operation condition and flashes at intervals of 500msec. If the condition is not changed for 3 seconds, it works at the displayed operation condition.

  • Page 58: Resetting The Boiler (Factory Reset)

    4.4.13 Cascade Protocol Settings If an error message appears, you can try resetting the boiler to You can connect one NCB-E boiler with up to 15 Navien water resolve the problem. To reset the boiler, press the Reset button. heaters, using the Ready-Link communication cables. Select the NCB-E series combination boiler in the cascade system as the master unit, and then connect the water heaters to it as slave units.

  • Page 59: Cascade Set-Up Procedure For Np/Nr Series Models

    4.4.14 Cascade Set-up Procedure 4.4.15 Cascade Set-up Procedure for NP/NR Series Models To configure the cascade communication settings: To configure the NR/NP series water heaters for a cascade system, 1. On the master NCB-E boiler, press and hold the [Diagnostic] follow the instructions below: and Up(+) buttons for more than 5 seconds.

  • Page 60: Version Display

    4.5 Version Display Item Description Display (a) Main Controller F/W Version Displays for 3 seconds (b) Panel F/W Version Ex > Ver 1.2 4.6 Error Codes Item Error Code Conditions Automatically releases the error code when the main controller doesn’t answer for 60 seconds but the system operates normal communications once.

  • Page 61: Ladder Diagram

    4.7 Ladder Diagram NEUTRAL EXT_PUMP Relay 1 FILTER Relay 2 VENTURI Relay 3 IGNITER Relay PUMP Relay 5 3 WAY Primary SMPS Speed Control DC15V Secondary DC24V DC12V 24V OUTPUT DC5V Auto Water 220V Supplement Flame Rod Flow Sensor H.T.L Hall Sensor DHW Inlet WD-PSS...

  • Page 62: Electrical Diagnostic Point & Wiring Diagram

    4.8 Electrical Diagnostic Point & Wiring Diagram System Details...
  • Page 63 Point Function CN No. Wire Color Normal Value Check DHW Inlet Temperature CN13 BLUE-BLUE DC 0-5V Voltage changes according to temperature. Sensor HEATING Return CN13 BLUE-BLUE DC 0-5V Voltage changes according to temperature. Temperature Sensor DHW outlet Temperature CN13 RED-RED DC 0-5V Voltage changes according to temperature.
  • Page 64 Point Function CN No. Wire Color Normal Value Check BLACK-RED DC 127-184V Confirm steady voltage. BLACK-YELLOW DC 15V Confirm steady voltage. Fan Motor BLACK-ORANGE DC 0-7.5V Voltage changes relative to fan operation. BLACK-WHITE 0-6500rpm Check PULSE. CN21 ON: DC 22-24V Auto Feeder Valve PURPLE- PURPLE OFF: 0V...

  • Page 65: Key Components Description

    4.9 Key Components Description 4.9.1 PCB Part Check Point Function To control each component and also to check the overall performance of the unit. Failure Event Malfunctioning PCB. A component may not operate within the unit and could produce an error code. In most cases of Effects PCB failure, the whole unit will not operate until the problem is resolved.

  • Page 66: High Limit Switch

    4.9.2 High Limit Switch Part Check Point 1. Overheat prevention switch. 2. If the unit detects extremely high temperatures, it will automatically trip and shut down the Function unit. 3. Excessively high water temperatures (more than 230 °F or 110 °C) in heat exchanger will activate the high limit switch.

  • Page 67: Thermistor

    4.9.3 Thermistor Part Check Point Function Measure Hot water, Cold water, Space heating outlet and inlet temperatures in the boiler. Failure Event Unable to properly measure water temperature within the boiler. 1. If any of the thermistors fail, an error code appears before starting operation. Effects 2.

  • Page 68: Fan Motor

    4.9.4 Fan Motor Part Check Point Provides combustion air into the burner and purges exhaust flue gas. Function Maintains the gas input with a long vent run, the fan operates with APS for ideal combustion. 1. Fan speed failure: the fan RPM is around 0 RPM. Failure Event 2.

  • Page 69: Flame Rod Assembly

    4.9.5 Flame Rod Assembly Part Check Point Function To ignite gas by repeatedly discharging a high voltage spark to the main burner until gas ignites. 1. Unable to ignite during the ignition process. Failure Event 2. Produces multiple unsuccessful attempts to ignite. 1.

  • Page 70: Ignition Transformer

    4.9.6 Ignition Transformer Part Check Point Function To ignite gas by repeatedly discharging a high voltage spark to the main burner until gas ignites. 1. Unable to ignite during the ignition process. Failure Event 2. Produces multiple unsuccessful attempts to ignite. 1.

  • Page 71: Aps

    4.9.7 APS Part Check Point Function Detects the air pressure in the combustion system. 1. Combustion noise occurs. Failure Event 2. Imperfect and/or abnormal flame occurs. 3. Occurs when APS does not detect proper voltage. 1. The boiler is not operating. Effects 2.

  • Page 72: Main Gas Valve

    4.9.8 Main Gas Valve Part Check Point 1. To control the amount of gas supplied to the burner based on fan speed. Function 2. When the unit experiences abnormal combustion, it shuts off the gas valve automatically and prevents unsafe situations. Failure Event Unable to open/close 1.

  • Page 73: Burner

    4.9.9 Burner Part Check Point 1. Pre-Mix system reduces emissions and increase efficiency. Function 2. The burner facilitates the air/gas mixture necessary to produce the proper heat during combustion. 1. Unable to initialize/sustain combustion. Failure Event 2. Dust or soot deposit on the burner surface 3.

  • Page 74: Flow Sensor

    4.9.10 Flow Sensor Part Check Point Function To detect water flow in GPM (Gallons Per Minute) for steady hot water temperatures. 1. Unable to detect or measure water flow rate. Failure Event 2. Damage to and/or water leakage from the water flow sensor. 1.

  • Page 75: Primary Heat Exchanger

    4.9.11 Primary Heat Exchanger Part Check Point 1. Main part for heat transfer from the burner. Function 2. There are multiple paths of water pipes on the heat exchanger surface as well as inside the combustion chamber which minimizes the heat loss. 1.

  • Page 76: Secondary Heat Exchanger

    4.9.12 Secondary Heat Exchanger Part Check Point 1. Main part for heat transfer from the burner. Function 2. There are multiple paths of water pipes on the heat exchanger as well as inside the combustion chamber which minimizes heat loss. 1.

  • Page 77: Dhw Heat Exchanger

    4.9.13 DHW Heat Exchanger Part Check Point Water heated in the primary/secondary heat exchanger is circulated to the plate heat exchanger, Function where the heat of heating water and tap water are exchanged so that hot water is available 1. Water leakage through a crack. Failure Event 2.

  • Page 78: Circulation Pump

    4.9.14 Circulation Pump Part Check Point 1. Pump operates when using internal or external hot water circulation. Function 2. Internal circulation will minimize the effect of temperature fluctuations and external circulation delivers hot water to fixtures quickly resulting in water conservation. Failure Event Unable to detect or measure water flow rate when the pump is called to operate.

  • Page 79: 3-Way Valve

    4.9.15 3-Way Valve Part Check Point Diverts the water from the space heating system to the DHW plate heat exchanger and back based Function on input from DHW flow sensor and PCB. 1. No hot water in space heating mode. Failure Event 2.

  • Page 80: Water Pressure Sensor

    4.9.16 Water Pressure Sensor Part Check Point Function They are suitable for analyzing water pressure ratios in heating. Failure Event Unable to detect or measure to change water pressure Effects Water filling system does not operate automatically Error Code E351, E352, E353 1.

  • Page 81: Auto Feeder Valve

    4.9.17 Auto feeder Valve Part Check Point Detect low and high water pressure using the electronic water pressure sensor If water pressure is Function low, Water filling system operates automatically 1. Water filling system does not operate automatically. Failure Event 2.

  • Page 82: Dual Venturi

    4.9.18 Dual Venturi Part Check Point To conrol the amount of mixed gas supplied with TDR of 10:1. Function It uses synchronous motor to control the amount of mixed gas by stage 1 and 2. 1. Blade not closing Failure Event 2.

  • Page 83: Troubleshooting

    5. Troubleshooting 5.1 Error code classification Classification Error Code Error Level Function Self-diagnostic/Action E003 Ignition failure Manual RESET E004 False flame detection Auto RESET E012 Flame loss Manual RESET E016 Overheating of heat exchanger Manual RESET Exhaust Overheat: exhaust limit switch shuts down the unit Combustion Manual RESET E030...

  • Page 84: Error Code List

    5.2 Error Code List Error Code Sub Code Function Self-diagnostic/Action Clean the Strainer ● Check the Pump for proper voltage from PCB(120AC) ● E001 Overheating of heat exchanger Check for proper flow rate and circulation through the ● heating line. Check the heat exchanger;...
  • Page 85 Error Code Sub Code Function Self-diagnostic/Action Check and clean the intake air filter. ● E109 Abnormal fan motor activity Verify proper voltage from PCB. ● Check and clean the fan motor. ● Check the intake/exhaust/condensate drain pipe for ● Exhaust blockage (checking the FAN) obstructions.(ice, snow, wildlife, etc) E110 Exhaust blockage (Using hot water)
  • Page 86 ● If any of the above solutions do not resolve the problem with the Boiler, contact Navien’s Technical department at 1-800-519-8794. There will be error codes displayed on the front panel and recorded on the PCB board (within the unit) of any problems or failures that occur with the Boiler.

  • Page 87: 001Error

    5.1.1 001Error Error occurrence conditions and check items Error Description 1. In order to prevent boiler in the heat exchanger, if the space heating water temperature is higher than 212 °F(100 °C), E001 will be displayed on the front panel. E001 Overheating of Heat 2.
  • Page 88 Check method Failure mode Cause Check method When check the circulation pump, the circulation pump and fan run continuously in the error condition, In the status not occurred error, set PCB DIP S/W #1 on and. Defective circulation pump 1. Check power supply to the circulation pump(AC 120V) 2.
  • Page 89 Failure mode Cause Check method Sudden increase of temperature due to PCB DIP S/W model setting error or max setting. DIP S/W No. Capacity 150,000 BTU (180) Capacity setting Other trouble 175,000 BTU (210) 199,000 BTU (240) 120,000 BTU (150) Defective PCB If the trouble continues despite the checking of above items, replace the PCB.

  • Page 90: 003Error

    5.2.2 003Error Error occurrence conditions and check items Error Description In the case of an ignition failure, the boiler will attempt ignition 10 times. If no flame is detected, the system E003 displays the error message 003E (manually cleared) on the Front Panel. Ignition failure Verify the information Data (K) for Flame State to check for proper operation(see page 44).
  • Page 91 Scenario2 Does the main Is gas valve operating Check connector gas valve have proper normally? voltage? Check the voltage between #1 and #2 of CN 16: 22-24 VDC Check the voltage between #1 and #3 of CON 4: 22-24 VDC (see page 18 for Wiring Diagram) Check that gas valve is open or Is gas valve open?
  • Page 92 Check method Failure mode Cause Check method 1. Check if the main gas valve is open. 2. Check the gas supply pressure. NG: 3.5” - 10.5” W.C, LP: 8” – 13.5” W.C ● LP pressure drop occurs frequently in the winter. ●...
  • Page 93 Failure mode Cause Check method Bracket Igniter Flame Red Ignite gap distance : 3.5-4.5mm (1/8”) When no spark is made from the electrode at ignition: Remove the electrode and check if there is a crack on the insulator. ● Adjust the gap if there is a discharge of electricity from the metallic part of the ●...
  • Page 94 Failure mode Cause Check method 1. Check the primary/secondary power supply to the main gas valve. Check, with a multi-meter, between the RED-YELLOW and WHITE-RED wires to ● verify that the input power is DC 22-24V 2. Replace the PCB if power is not supplied. Main gas valve 3.
  • Page 95 Failure mode Cause Check method 1. Check the location of the flame, if there is any deformation or foreign substance, repair or replace the part. 2. Check the flame rod wire for proper connection and/or damage. Flame sensing error 3. Check the grounding to the boiler case to verify proper grounding at the outlet. If the ground wire is improperly connected or not making a good connection, ●...

  • Page 96: 004Error

    Failure mode Cause Check method Check if there are any Ignition failure will occur if the gas orifices are clogged. Flame loss and noise blockages in the gas occurs at ignition Remove the gas inlet pipe and check the orifice plate. ●...
  • Page 97 Check method Failure mode Cause Check method Flame before/after Leakage from main gas Replace the gas flame if flame occurs before combustion or if there is remaining flame combustion valve after combustion is stopped. Spark discharges from electrode to flame sensor at ignition. Discharge of electricity from electrode Replace or correct location of flame detecting rod.

  • Page 98: 012Error

    5.2.4 012Error Error occurrence conditions and check items Error Description If the system detects loss of flame during combustion, the system stops supplying fuel, E012 attempts to restart, counts the incidents of flame loss, and if the incident occurs 20 times Flame loss consecutively displays 012E (manually cleared) on the front panel.
  • Page 99 Check method Fault Possible Causes Check method 1. Check if a gas valve is opened or not. 2. Check the gas supply pressure. NG: 3.5” - 10.5” W.C, LP: 8” - 13.5” W.C ● LP pressure drop occurs frequently in the winter. ●...
  • Page 100 Fault Possible Causes Check method Replace the electrode or clean the fire detecting electrode. Cause: Due to the properties of the electrode, the oxide film is created due to ● long-term exposure to the high temperature; therefore, errors may be caused in detecting the fires.
  • Page 101 Fault Possible Causes Check method Model Gas Type Offset -0.04 in ±0.01 in NCB-150E -0.03 in ±0.01 in -0.04 in ± 0.01 in NCB-180E Flame loss and noise -0.03 in ± 0.01 in occurs after ignition -0.04 in ± 0.01 in NCB-210E -0.02 in ±...

  • Page 102: 016Error

    5.2.5 016Error Error occurrence conditions and check items Error Description If the overheat controller on the heat exchanger is initiated during combustion/standby of the E016 boiler, the system displays the 016E (manually cleared) message on the front panel. The boiler Bimetal overheated switches into Lock-Out, and performs post-purge continuously and operates the pump.
  • Page 103 Check method Fault Possible Causes Check method Check if the contact point of the overheat controller is defective. Defective overheat controller Use a multi-meter to see if the resistance is normal (0.3Ω) or abnormal (∞). ● Overheat controller Defective safety device Check if the overheat controller wire is disconnected ( Normal resistance : 0.3Ω...

  • Page 104: 030Error

    5.2.6 030Error Error occurrence conditions and check items Error Description If the overheat controller on the top of the exhaust duct is initiated, the system displays the heat exchanger bimetal overheat message 030E (cleared manually) on the front panel. The boiler switches into Lock-Out, and performs post-purge continuously and operates the pump.
  • Page 105 Check method Fault Possible Causes Check method 1. The error occurs due to high exhaust gas temperature caused by a damaged or clogged heat exchanger. Heat exchanger Damaged or clogged overheated heat exchanger 2. Flush the heat exchanger to remove scale deposits. 3.

  • Page 106: 046Error

    5.2.7 046Error Error occurrence conditions and check items Is heat exchanger Check connector thermistor normally ( #3 and #4 of CN 13) operating? Is resistance 1 step: Flushing, Clean Filter within normal range? 2 step: Try to restart (refer to page 66) 3 step: Replace PCB Replace heat exchanger thermistor.

  • Page 107: 060Error

    5.2.9 060Error Error occurrence conditions and check items Error Description This error message is displayed on the front panel if the wiring is disconnected or the Dual E060 Venturi malfunctions. Dual Venturi error The boiler switches into Lock-Out, and performs post-purge continuously and operates the pump.
  • Page 108 Check method Fault Possible Causes Check method 1. Disconnect all cables from the Dual Venturi. Defective Dual Venturi cable or harness 2. Using a multi-meter, test the Dual Venturi electrical wiring. 1. Turn off the power to the unit using the main power switch (do not use the front panel power button) and wait for 10 seconds.

  • Page 109: 109Error

    5.2.10 109Error Error occurrence conditions and check items Error Description The system checks the RPM signal after the fan starts to run, and displays the error message 109E (cleared manually) in the following cases: 1. If the RPM remains low or close to 0, the system determines RPM error, and the boiler switches into Lock-Out (gas valve and ignition transformer locked).
  • Page 110 Check method Fault Possible Causes Check method 1. Check the power supply to the blower. Black + Red, approx. DC 127-184 V ● 2. Replace the PCB if voltages are abnormal. (When replacing the PCB, turn off No fan operation the unit and then wait for at least 10 seconds before proceeding.) 3.

  • Page 111: 110Error

    5.2.11 110Error Error occurrence conditions and check items Error Description The system senses the air volume and the RPM signal, and displays 110E on the front panel in the following cases: E110 1. When the initial fan auto-adjust is not performed. Air pressure error 2.
  • Page 112 Check method Fault Possible Causes Check method 1. If 110E occurs intermittently during ignition or combustion, compare the standard RPM with the current RPM at Min / Max combustion (dip switch 1-1&1-2). If the current RPM is higher than normal, check the following: 110E Abnormal flow of intake Air supply / exhaust vent for any blockages.

  • Page 113: 205Error

    5.2.12 205Error Error conditions and Check Items Error Description E205 If an error (open: 14°F (-10°C) or lower) in the heat exchanger input temperature sensor is Heat exchanger output temperature detected, the system displays the 421E error on the front panel. If this occurs, the boiler initiates sensor open shutdown.
  • Page 114 Check method Fault Possible Causes Check method Defective temperature Check if the temperature sensor is open and if the connector is connected sensor connector properly. Defective sensor Check the resistance of the temperature sensor. (Defective if it is 30kΩ or higher) Temperature sensor Replace the temperature sensor if the resistance value is abnormal.

  • Page 115: 218Error

    5.2.13 218Error Error conditions and Check Items Error Description E218 If an error (open: 14°F (-10°C) or lower) in the heat exchanger input temperature sensor is Heat exchanger input temperature sensor detected, the system displays the 421E error on the front panel. If this occurs, the boiler initiates open shutdown.
  • Page 116 Check method Fault Possible Causes Check method Defective temperature Check if the temperature sensor is open and if the connector is connected sensor connector properly. Check the resistance of the temperature sensor. (Defective if it is 30kΩ or higher) Defective sensor Replace the temperature sensor if the resistance value is abnormal.

  • Page 117: 351Error

    5.2.14 351Error Error conditions and Check Items Error Description If the water pressure sensor senses low water level as the heating pipe pressure is low, the E351 system stops operation of the boiler, and refills water automatically. Abnormal Auto feeder valve If water is supplied by auto feeder valve open over 5 minutes, the error(E351) is detected and displayed on the front panel.
  • Page 118 Check method Fault Possible Causes Check method Water is not Cold water valve is closed Turn on cold water tap and check if the valve works or is frozen. Refilled or frozen 1. Check the auto feeder valve filter if water is not refilled. 2.

  • Page 119: 352Error

    5.2.15 352Error Error conditions and Check Items Error Description Upon receiving a signal from the water pressure sensor, the system displays the error(E352) on E352 front panel. High water pressure High water level error if the water level of 56.6 psi or higher continues 3 seconds. Error is automatically cancelled if water level is 43.5 psi or lower.

  • Page 120: 353Error

    5.2.16 353Error Error conditions and Check Items Error Description If an error (under 0.3V or over 2.8V) in the water pressure sensor is detected continuously for E353 3 seconds, The system displays the error message E353 on the front panel. If this occurs, the Abnormal water pressure sensor boiler initiates shutdown.

  • Page 121: 407Error

    5.2.17 407Error Error conditions and Check Items Error Description E407 If an error (open: 14°F (-10°C) or lower) in the DHW Outlet Elbow input temperature sensor is Hot water outlet thermistor open or short detected, the system displays the 407E error on the front panel. 1.
  • Page 122 Check method Fault Possible Causes Check method Defective temperature Check if the temperature sensor is open and if the connector is connected sensor connector properly. Check the resistance of the temperature sensor. (Defective if it is 30kΩ or higher) Defective sensor Replace the temperature sensor if the resistance value is abnormal.

  • Page 123: 421Error

    5.2.18 421Error Error conditions and Check Items Error Description E421 If an error (open: 14°F (-10°C) or lower) in the DHW Outlet Elbow input temperature sensor is Cold water inlet thermistor open or short detected, the system displays the 421E error on the front panel. 1.
  • Page 124 Check method Fault Possible Causes Check method Defective temperature Check if the temperature sensor is open and if the connector is connected sensor connector properly. Check the resistance of the temperature sensor. (Defective if it is 30kΩ or higher) Defective sensor Replace the temperature sensor if the resistance value is abnormal.

  • Page 125: 439Error

    5.2.19 439Error Error occurrence conditions and check items Error Description As one or more units are operating in the cascade system, if no flow is detected during DHW E439 using, the system considers it as a defective flow sensor. The system displays 439E (cleared Flow sensor error manually) on the front panel and switches the unit operation into the Lock-Out mode (gas valve and ignition transformer locked).
  • Page 126 Fault Possible Causes Check method 1. Check the current flow displayed on the front panel. If the flow sensor is defective, the displayed flow value is 0.0 while water ● flows from the hot water tap. Remove the flow sensor and blow into it. The rotation detector on the flow ●...

  • Page 127: 515Error

    5.2.20 515Error Error occurrence conditions and check items Error Description If an error occurs in the internal circuit of the PCB (e.g., resistance, transistor or relay fault), the E515 error system displays 515E (cleared manually) on the PCB. 1. Defective PCB 2.

  • Page 128: 517Error

    5.2.21 517Error Error occurrence conditions and check items Are the DIP S/W on the PCB Reset the unit properly set? Change the DIP S/W to the proper settings 5.2.22 594Error Error occurrence conditions and check items Error Description E594 error If the communication is abnormal in parts of PCB, the system displays E594 on the PCB.

  • Page 129: 740Error

    5.2.24 740Error Error conditions and Check Items Error Description If an error (under 2.2kΩ or over 122.2kΩ) in the outdoor sensor is detected continuously for E740 3 seconds, The system displays the error message E740 on the front panel. If this occurs, the Abnormal outdoor sensor boiler changes the control mode from Reset Curve Mode to Normal Mode.

  • Page 130: 777Error

    5.2.25 777Error Error conditions and Check Items Check the factory Is the LWCO Is the factory jumper installed jumper installed properly? installed properly and jumper on CN24? connection (CN24) Check the Is the output Is proper power being connecting voltage normal on supplied to the LWCO? terminals CN25? (AC 24V)

  • Page 131: 782Error

    5.2.26 782Error Error occurrence conditions and check items Is the wiring from the 1. step: Reset the unit. front panel properly 2. step: If problem persists, replace connected to the PCB? the PCB and Front panel. Reconnect panel to the PCB NCB-E Service Manual Version 1.4...

  • Page 132: Troubleshooting Guide By Symptom

    5.3 Troubleshooting guide by symptom 5.3.1 Noise Error type Cause Check method Incorrect mounting to the wall or in an improper location. Defective installation Check for improper installation and reinstall the unit if necessary. ● Vibration caused due to defective blower. Vibration noise Check the blower.

  • Page 133: Water Temperature Issue

    5.3.2 Water Temperature Issue Error type Cause Check method Front panel power off Hot water does not run if the front panel is switched off. The boiler does not work due to the defective flow sensor. The flow sensor impeller will not rotate if it contains excessive scale or debris. Clean ●...

  • Page 134: Circuit Breaker Operation

    5.3.3 Circuit breaker operation Error type Cause Check method The circuit breaker trips immediately as soon as the power cord is plugged in the receptacle. Power supply Check the sheath of power cord, or if there is short-circuit. Check the components in order from the power transformer to the PCB. If the circuit breaker operates after repairs check the wiring of each part.

  • Page 135: Replacement Of Parts

    5. Disconnect all wiring connectors from the PCB a screwdriver that is at least 8-10 inches long. A flashlight and magnetic tip are also recommended. Navien recommends the use of a parts tray to hold small parts and screws. All of the hardware is essential to the proper operation of the unit upon re-assembly.

  • Page 136: Fuse

    6.2.3 Fan Motor (Combustion Air) 7. Remove the old PCB and replace it with the new part. 8. Reattach all wiring connectors to the PCB. 1. Turn off the gas supply to the unit. 9. Set the proper DIP S/W settings on the PCB (refer to page 131). 2.

  • Page 137: Flame Rod

    8. Remove the four screws from the bottom of the fan assembly. 5. Remove the 2 screws from the flame rod as shown in Figure 7 below. Figure 7 Figure 6 6. Remove the flame rod wiring connector. 9. Detach the fan motor from the assembly and replace it with the new part.

  • Page 138: Ignition Transformer

    6.2.5 Ignition Transformer 11. Turn on water supply, power supply, and gas supply to the unit. 1. Turn off the gas supply to the unit. NOTE 2. Disconnect the unit from the power supply. 3. Turn off the water supply to the unit. Verify that the Ignition Transformer insulated cables are firmly connected to the flame rod.

  • Page 139: Main Gas Valve

    6. Remove the 2 screws that attaches the air pressure sensor to 7. Disconnect wiring connector from the Front Panel. the burner assembly. 7. Pull out the air pressure sensor. 8. Replace the old air pressure sensor with the new part. 9.

  • Page 140: Condensate Trap

    11. Remove the 4 screws directly on the bottom of the gas valve to 18. Turn on water supply, power supply, and gas supply to the remove the gas pipe. unit. 19. Verify the gas pressures to the unit with the values provided in this Service Manual.

  • Page 141: Flow Sensor

    12. Turn on the water supply, power supply, and gas supply to the 7. Detach the 3 wire connectors that connect the flow sensor to unit. the PCB. NOTE Ensure that the condensate drain trap is completely inserted into the condensate fitting to eliminate leaking. Use the pin to secure the cap to the fitting.

  • Page 142: Circulation Pump

    6.2.10 Circulation Pump 6. Carefully remove the pump. 1. Turn off the gas supply to the unit. 2. Disconnect the unit from the power supply. 3. Turn off the water supply to the unit. 4. Open the drain plug on the pump and Remove the 4 screws from the bottom of the case.

  • Page 143: 3-Way Valve

    10. Secure the pump with the stainless steel clip and the 2 fixing screws. NOTE Always use proper O-rings at the pump connection to ensure tight seals 6.2.11 3-way Valve 1. Turn off the gas supply to the unit. 2. Turn off the 120V power supply to the unit. 3.

  • Page 144: Water Pressure Sensor

    6.2.12 Water Pressure Sensor 4. Remove the stainless pin from the space heating strainer body. 1. Turn off the gas supply to the unit. 2. Turn off the 120V power supply to the unit. 3. Turn off the water supply to the unit. Drain all water from the appliance.

  • Page 145: Auto Feeder Valve

    6.2.14 Auto Feeder Valve 5. Remove the Domestic Hot Water Outlet collar. 1. Turn off the gas supply to the unit. 2. Turn off the 120V power supply to the unit. 3. Turn off the water supply to the unit. Drain all water from the appliance.

  • Page 146: Components Diagram And Part List

    7. Components Diagram and Part List 7.1 Case Assembly Description Part # Remark Intake Air Duct Assembly 30008662B Exhaust Pipe Assembly 30008673A 20027375A NCB Models Case 20033278A NCB-E Models Intake Air Filter 20007667A NCB Models 30010238A NCB Models Air Pressure Sensor 30010346A NCB-E Models 30012262A...

  • Page 147: Burner Assembly

    7.2 Burner Assembly NCB-E Service Manual Version 1.4...
  • Page 148 Description Part # Remark Damper 30008825A O-Ring (G50) 20003019A Fan Bracket 20022095A Siphon 30012280A 20030283A NCB-150E Burner Chamber Ass'y 30010353A NCB-180E 30008440A NCB-210E/240E Ignition Transformer 30010455A 20027105A NCB-150E Burner Packing 20021677A NCB-180E 20021672A NCB-210E/240E 30014697A NCB-150E 30012322A NCB-180E Heat Exchanger Ass'y...

  • Page 149: Waterway Assembly (Ncb)

    7.3 Waterway Assembly (NCB) 35 16 *Before 2015.5.15 prduced units only. Description Part # Remark 30008181A NCB-180 DHW Heat Exchanger 30005017A NCB-210/240 Fastener 20007858A O-Ring (P18) 20006954A NCB-E Service Manual Version 1.4...
  • Page 150 Description Part # Remark DHW Outlet Elbow 30012328A Packing 20006852A Thermistor 30008366A DHW Outlet Adaptor 30003747A DHW Flow Sensor 30012033B O-Ring (P14) 20006952A 30010315A NCB-180 DHW Cold Water Adaptor 30010316A NCB-210 30010317A NCB-240 O-Ring (P20) 20017212A DHW Cold Water Filter 30007878A Air Vent 30012277A...

  • Page 151: Waterway Assembly (Ncb-E)

    7.4 Waterway Assembly (NCB-E) 35 16 Description Part # Remark 30015581A NCB-150E DHW Heat Exchanger 30008181A NCB-180E 30005017A NCB-210E/240E Fastener 20007858A O-Ring (P18) 20006954A DHW Outlet Elbow 30012328A Packing 20006852A Thermistor 30008366A NCB-E Service Manual Version 1.4...
  • Page 152 Description Part # Remark DHW Outlet Adaptor 30003747A DHW Flow Sensor 30012033B O-Ring (P14) 20006952A 30015582A NCB-150E 30010315A NCB-180E DHW Cold Water Adaptor 30010316A NCB-210E 30010317A NCB-240E O-Ring (P20) 20017212A DHW Cold Water Filter 30007878A Drain Cock 30008630B NCB E Models Only...

  • Page 153: Fan (Gas) Assembly

    7.5 Fan (Gas) Assembly NCB-E Service Manual Version 1.4...
  • Page 154 Description Part # Remark 30015586A NCB-150 Fan Assembly 30008834A NCB-180/210/240 Fan Packing 20022744A O-Ring (G75) 20018079A 30015587A NCB-150 Dual Venturi 30010672A NCB-180 30008909A NCB-210/240 20030064A NCB-150 Silence 20019142A NCB-180 20023829A NCB-210/240 20033736A NCB-150 Silence Adaptor 20023861A NCB-180 20019141A NCB-210/240 Venturi Packing 20022660A NCB-180 20033737A...

  • Page 155: Inspection And Maintenance Schedule

    8. Inspection and Maintenance Schedule 8.1 Annual Servicing 8.3 Maintenance Schedules In order to maintain its safe and efficient operation, it is Owner maintenance recommended that the boiler is serviced annually. Check boiler area ● Daily Check pressure / temperature gauge ●...
  • Page 156 Memo...
  • Page 157 Memo...

This manual is also suitable for:

Ncb-180eNcb-210eNcb-240e

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