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Navien NCB-190/060H Installation & Operation Manual

Condensing combi-boilers
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Installation & Operation Manual
NCB-H Condensing Combi-Boilers
Model
NCB-190/060H
NCB-190/080H
NCB-240/110H
NCB-240/130H
NCB-250/150H
NSF/ANSI 372
H
WARNING
If the information in these instructions is not followed exactly, a fire or explosion may
result, causing property damage, personal injury, or death.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any
other appliance.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
●
Do not touch any electrical switch; do not use any phone in your building.
●
Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
●
If you cannot reach your gas supplier, call the fire department.
●
Installation and service must be performed by a qualified installer, service agency or the gas
supplier.
The installation must conform with local codes or, in the absence of local codes, the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Code.
Keep this manual near this boiler for future reference
whenever maintenance or service is required.
* The wetted surface of this product contacted by consumable water
contains less than one quarter of one percent (0.25%) of lead by weight.

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Summary of Contents for Navien NCB-190/060H

  • Page 1 Installation & Operation Manual NCB-H Condensing Combi-Boilers Model NCB-190/060H NCB-190/080H NCB-240/110H NCB-240/130H NCB-250/150H 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 2 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 4.00 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...

  • Page 3: Table Of Contents

    9. Installing a Common Vent System 82 2. Installing the Boiler 9.1 About the Common Vent System 2.1 Choosing an Installation Location 9.2 Navien Common Vent Collar Kit (Back- 2.2 Mounting the Boiler to the Wall draft Damper) 9.3 Starting the Common Vent System 3.
  • Page 4 Safety Information The following safety symbols are used in this manual. Read and follow all safety instructions in DANGER this manual precisely to avoid 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 boiler unless the water ● and gas supplies are fully opened. Doing so may damage the boiler. Do not use this boiler for anything other ● than its intended purpose, as described in this manual.
  • Page 6 DANGER DANGER This boiler’s DHW temperature is set to 120°F (49°C) at the factory for your safety and comfort. Increasing the temperature increases the risk of accidental scalding. Water temperatures at or above 125°F (52°C) can cause instant scalding, severe burns, or death. Before you decide to change the temperature setting, read the following charts carefully.

  • Page 7: About The Boiler

    Anchors (x4) Navi-Link Ready-Link Rack (Wi-Fi Control System) Pressure Relief Valve, Propane Conversion Kit* Heating NaviClean Navien Manifold System Outdoor Temperature Spare Parts Sensor and Cable HotButton Push Button HotButton Wall Plate High Altitude Conversion The Universal Temperature Sensor can...

  • Page 8: Specifications

    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 9 The NCB-H boiler is equipped with an internal circulation pump. The following table provides detailed information on the pump used for the boiler and the performance curve. Item Pump Model NCB-190/060H, NCB-190/080H, Grundfos UPS 15-78 CIAO2 NCB-240/110H, NCB-240/130H, NCB-250/150H (Part Number: 30023987A)
  • Page 10 General Specifications NCB- NCB- NCB- NCB- Item NCB-250/150H 190/060H 190/080H 240/110H 240/130H Dimensions 17.3 in (W) x 29.3 in (H) x 12.8 in (D) Boiler Weight 87 lbs (40 kg) 96 lbs (44 kg) Boiler Weight with Water 93 lbs (42 kg) 102 lbs (46 kg) Installation Type Indoor Wall-Hung...

  • Page 11: Components

    1.4 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 Vent Installation Detector Flue Duct Mixing Chamber Ignitor & Flame Air Vent Front Panel Circulation Pump Power Switch...
  • Page 12 Pressure Relief Valve Adapter Vent Installation Fan & Motor Detector Dual Venturi High Limit Switch Premix Burner Ignitor & Flame Rod Primary Heat Exchanger Air Pipe Secondary Heat Exchanger Pressure Sensor (LWCO) Gas Valve Gas Pipe Mixing Valve Water Adjust Valve DHW Exchanger 3-Way Valve Water Fill Valve...

  • Page 13: Dimensions

    1.5 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 ¾ in Air Intake 2 in Exhaust Gas Vent 2 in Heating Supply 1 in Domestic Hot ¾...

  • Page 14: Rating Plate

    1.6 Rating Plate The Navien NCB-H boilers come from the factory configured for use with Natural Gas (NG). Before starting the installation, check the rating plate located on the side of the boiler to ensure that the boiler matches the gas type, gas pressure, water pressure, and electrical supply available in the installation location.

  • Page 15: Installing The Boiler

    Navien will not be responsible for water damages that occur as a result. For more information about condensate drainage, refer to “3.3 Connecting the Condensate Drain”...
  • Page 16 Adequate Venting and Ventilation Adequate Installation Clearances Select a location that requires minimal venting. Consider venting restrictions caused by windows, CAUTION doors, air intakes, gas meters, foliage, and other buildings. For more information about venting, refer Do not install the boiler on carpeting. to “5.

  • Page 17: Mounting The Boiler To The Wall

    2.2 Mounting the Boiler to the Wall Combustion Air Do not install the boiler in areas where dust and Navien NCB-H boilers come with an upper ● debris may accumulate or where hair sprays, mounting bracket that is pre-drilled at 16 in...
  • Page 18 WARNING The boiler is heavy. Always lift the unit with ● assistance. Be careful not to drop the boiler while lifting or handling it to avoid bodily injury or damage to the unit. Do not rest the boiler on the bottom end ●...

  • Page 19: Installing The System Piping

    When using the freeze protection products, the ● system must be tested at least once a year, and as The water-tube type heat exchanger of the Navien recommended by the manufacturer of the glycol NCB-H boiler is designed to attain the highest level solution.
  • Page 20 To obtain the minimum system design pressure, follow the piping diagrams Internal LWCO illustrated in this section. The Navien NCB-H boiler is equipped with a factory- The Navien NCB-H boiler’s space heating system ● installed, pressure-sensing type low water cutoff is not approved for operation in an “open system”,...
  • Page 21 Figure 2. External LWCO For diaphragm expansion tanks, always install ● (with Navien Manifold System) an automatic air vent on the top side of the air separator to remove residual air from the system. The external LWCO must be installed at least 6 in (152 mm) above the top of the heat exchanger.
  • Page 22 Ensure that the discharge line provides complete ● and unobstructed drainage. Do not install a WARNING reducing coupling or other restrictions on the discharge line. Installing the pressure relief valve improperly ● may result in property damage, personal If the relief valve discharges periodically, this may be injury, or death.

  • Page 23: Installing A Domestic Hot Water (Dhw) System

    Water (DHW) System proper space heating flow and inspect for leaks. Instruct the boiler owner that the strainer must The Navien NCB-H boiler provides domestic hot be cleaned periodically to maintain proper space water continuously when water flow is detected by heating water flow.
  • Page 24 Zinc Up to 5 mg/l approved for use with the boiler: Navien is not responsible for performance issues of the domestic system by scaling or accumulation of Wilkins P-1000A (Zurn Industries) ● dirt; suitable steps shall be taken by the installer and Conbraco 17-402-04 ●...
  • Page 25 Tighten the connection valves with care to avoid ● damage. CAUTION Navien recommends using unions and manual ● To comply with ASME or CRN requirements, shut-off valves on domestic cold and domestic an additional high temperature limitation hot.

  • Page 26: Connecting The Condensate Drain

    Drain b. From the boiler, through a neutralizing agent, and then into an external drain The Navien NCB-H boiler creates condensation when it operates. This condensation has an acidic If you choose this option, the Note pH of 3-5. Follow all local codes and regulations neutralizing agent must be when disposing of condensate from the boiler.
  • Page 27 If option ‘b’ is selected for condensate disposal, the obstructed in any other manner, condensate Navien condensate neutralizer kit is recommended. can exit from the tee, resulting in potential The condensate from the appliance flows through water damage.
  • Page 28 Installation The inlet has a center connection port and the ● outlet has an offset connection. Install the neutralizer on the wall or the floor and ● secure it using the brackets supplied with the kit. If the neutralizer is installed horizontally, rotate ●...

  • Page 29: Filling The System

    3.4.1 Built-in Water Fill Connection level is not specified, replace the neutralizing media when the pH is below 6.0. For replacement media, The Navien NCB-H boiler is equipped with an auto- contact your local Navien distributor. feeding water connection and motorized feeding valve.

  • Page 30: Testing The Water System

    3.4.2 External Water Fill Connection 3.5 Testing the Water System External water fill connection may be installed on the system piping if it is required for specific WARNING applications. See the following figure for an example of external water fill installation on the system Ensure that the boiler is full of water before piping.

  • Page 31: Considerations For System Applications

    3. Fill the boiler to the correct system pressure. Read and follow the guidelines listed below when The correct pressure will vary with each installing system piping for the Navien NCB-H boiler: application. The typical cold water fill pressure for a residential system is 12 psi. The operating System application drawings are intended to ●...
  • Page 32 Air Handler. the expansion tank. Air Handler Interface The Navien NCB-H boiler can control the operation of an air handler when a thermostat is used in combination with the air handling unit. The Air Handler Interface is designed to stop air handler operation when the boiler’s space heating function...
  • Page 33 Configuring a Zone System 3.6.2 Examples of System Applications Refer to the following examples to properly The NCB-H boiler can control up to 3 zones utilizing implement a system for space heating, DHW zone valves or zone pumps. After installing the supply, or both.
  • Page 34 3.6.3 System Application - Zone System with Pumps (Primary/Secondary Piping) Additional Zone Zone #2 Zone #1 NaviClean (recommended) Air Separator Pressure Relief Not to exceed 4 pipe Dia or Max. 12" Valve Backflow preventer Pressure reducing valve Expansion Tank Make-up Water System application drawings are intended to explain the system piping concept only.
  • Page 35 3.6.4 System Application - Zone System with Zone Valves (Primary/Secondary Piping) Additional Zone Zone #2 Zone #1 Zone Valve System Pump (Typical) NaviClean (recommended) Air Separator Not to exceed 4 pipe Dia or Max. 12” Make-up Water Backflow preventer Pressure reducing valve Expansion Tank System application drawings are intended to explain the system piping concept only.
  • Page 36 3.6.5 System Application - Air Handler System Pressure Relief Valve NaviClean (recommended) Air Separator Make-up Water Backflow preventer Expansion Tank Pressure reducing valve Air Flow Air Handler System application drawings are intended to explain the system piping concept only. Note ●...
  • Page 37 3.6.6 System Application - Air Handler System with RS-485 Communication Pressure Relief Valve NaviClean Air Separator COMM Cable Make-up Water Expansion Backflow preventer Tank Pressure reducing valve Air Flow Air Handler Thermostat Outdoor Sensor System application drawings are intended to explain the system piping concept only. Note ●...
  • Page 38 3.6.7 System Application - Combi Pre-Heat Mode Combi pre-heat allows NCB-H boilers to pre-heat to ensure a quick supply of hot water when there is no external recirculation system. This mode is enabled by default. (Refer to the combi pre-heat section in “11.5.3 Setting the DHW Operation”...
  • Page 39 3.6.9 External Recirculation with HotButton and Dedicated Return Line (HotButton, Aquastat) External Recirculation Mode To use the aquastat mode, install an aquastat to the DHW pipe line and connect to the CNC6 terminal on the PCB. (Refer to “3.7.4 Wiring Diagram - Zone Pump System with DHW Recirculation” on page 43 for details.) CAUTION The aquastat temperature must be set lower than the NCB-H boiler DHW set temperature.

  • Page 40: Examples Of Electrical Connections

    3.7 Examples of Electrical Connections WARNING Improperly connecting the electrical supplies can result in electrical shock and electrocution. Follow all applicable electrical codes of the local authority having jurisdiction. Connecting the electrical components should be performed only by a licensed professional. CAUTION 3.7.2 Wiring Diagram - External LWCO Label all wires before disconnecting them...
  • Page 41 3.7.3 Wiring Diagram - Zone Pump System NCB-H boilers can operate a heating system with up to 3 zones. The following is the wiring diagram for a zone pump system with 3 zones. Without 24VAC Connections lLWCO AC24VL AC24VN Zone pump 1 SUPPLY RETURN OUTDOOR...
  • Page 42 With 24VAC Connections lLWCO AC24VL AC24VN SUPPLY RETURN OUTDOOR T/S_ZONE3 T/S_ZONE2 T/S_ZONE1 Zone pump 1 TEMPERATURE SENSOR SUPPLY RETURN OUTDOOR T/S_ZONE3 T/S_ZONE2 T/S_ZONE1 (max. 2.5 A) TEMPERATURE SENSOR Zone pump 2 (max. 2.5 A) Zone pump 3 Pump Ground Thermostat 3 (max.
  • Page 43 3.7.4 Wiring Diagram - Zone Pump System with DHW Recirculation NCB-H boilers can use both the 3 zone heating system and the DHW recirculation feature. The following wiring diagram shows the 3 zone system and the DHW external recirculation feature. Without 24VAC Connections lLWCO AC24VL...
  • Page 44 With 24VAC Connections lLWCO AC24VL Recirculation pump AC24VN (max. 2.5 A) Recirculation Timer, Aquastat, lLWCO lLWCO AC24VL AC24VL AC24VN AC24VN or HotButton SUPPLY SUPPLY RETURN RETURN OUTDOOR OUTDOOR T/S_ZONE3 T/S_ZONE3 T/S_ZONE2 T/S_ZONE2 T/S_ZONE1 T/S_ZONE1 Push Button Zone pump 1 TEMPERATURE SENSOR TEMPERATURE SENSOR SUPPLY RETURN...
  • Page 45 3.7.5 Wiring Diagram - Zone Valve System The NCB-H Boilers can operate a heating system with up to 3 zones. The following is the wiring diagram for a zone valve system with 3 zones. Without 24VAC connections Zone valve 1 (max.
  • Page 46 With 24VAC connections Zone valve 1 (max. 0.75 A) Zone valve 2 (max. 0.75 A) Zone valve 3 (max. 0.75 A) lLWCO AC24VL Recirculation pump AC24VN (max. 2.5 A) Recirculation Timer, Aquastat, lLWCO AC24VL AC24VN or HotButton SUPPLY RETURN OUTDOOR T/S_ZONE3 T/S_ZONE2 T/S_ZONE1...
  • Page 47 3.7.6 Wiring Diagram - the Navien SmartZone + The Navien Smart Zone + controller may be used with NCB-H boilers to operate a heating system with more than 3 zones. When Navien boilers are used with a Navien Smartzone+ zone pump controller, an RS-485 data communication link is established through the Ready-link connection.
  • Page 48 3.7.7 Wiring Diagram - Generic Zone 3.7.8 Wiring Diagram - Generic Zone System with Zone Valves System with Zone Pumps <NCB-H> <NCB-H> lLWCO lLWCO AC24VL AC24VL AC24VN AC24VN SUPPLY RETURN OUTDOOR T/S_ZONE3 T/S_ZONE2 T/S_ZONE1 SUPPLY RETURN OUTDOOR T/S_ZONE3 T/S_ZONE2 T/S_ZONE1 TEMPERATURE SENSOR TEMPERATURE SENSOR SUPPLY...
  • Page 49 3.7.9 Wiring Diagram - Air Handler <NCB-H> lLWCO AC24VL AC24VN SUPPLY RETURN OUTDOOR T/S_ZONE3 T/S_ZONE2 T/S_ZONE1 TEMPERATURE SENSOR SUPPLY RETURN OUTDOOR T/S_ZONE3 T/S_ZONE2 T/S_ZONE1 TEMPERATURE SENSOR <Air Handler> Connect the pump wires to the system pump. <NCB-H> lLWCO AC24VL AC24VN SUPPLY RETURN OUTDOOR...
  • Page 50 2. Space Htg Operation > 5. SH Control Method to select one of the control modes. For best performance, wrap the sensor and pipe section with thermal insulation. ● Universal temperature sensors are available for purchase. Contact Navien for more information. ● Installing the System Piping...

  • Page 51: Connecting The Gas Supply

    This boiler cannot be converted from natural ● gas to propane or vice versa without a Navien gas conversion kit. Do not attempt a field conversion of this boiler without a Navien gas conversion kit. Doing so will result in dangerous operating conditions and will void the warranty.
  • Page 52 BTUs. Also, ensure that the flexible line has no crimps or tight bends in it, as this will restrict gas flow. Gas Supply When using rigid pipe, Navien ● recommends the installation of a union on the gas supply line close to the boiler, to facilitate any future maintenance or service.
  • Page 53 Typical LP Gas piping examples: CAUTION 2 Stage System with Multiple Prior to using an excess flow valve (EFV) in the Regulators (Recommended) gas line, check the manufacturer’s minimum and maximum flow capacity rating. An improperly sized EFV will not allow for a full flow of gas to Gas Regulator (2 Stage) the boiler and may cause improper operation.

  • Page 54: Gas Pipe Sizing Tables

    4.1 Gas Pipe Sizing Tables The following tables are referenced from the 2012 National Fuel Gas Code and 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;...

  • Page 55: Measuring The Inlet Gas Pressure

    Maximum Liquefied Propane Delivery Capacity In Thousands of BTU/H (0.5 in WC pressure drop) Length (including fittings) Pipe Size 10 ft 20 ft 30 ft 40 ft 50 ft 60 ft 80 ft 100 ft 125 ft 150 ft 175 ft 200 ft 250 ft (3 m)
  • Page 56 To measure the inlet gas pressure: 8. Unfasten the 4 latches (2 at the top and 2 at the bottom) to remove the front cover and gain 1. Shut off the manual gas valve on the gas supply access to the internal components. line.

  • Page 57: Venting For Combustion Air

    5. Venting for Combustion Air Additional Guidelines for Combustion Air Corrosive Contaminants Muriatic acid/hydrochloric acid Combustion air piping to the outside is ● recommended. (Direct Venting) Refrigerant leaks The boiler may be installed with a single pipe ● Chlorine-type bleaches, detergents, and cleaning carrying the flue products to the outside while solvents found in household laundry rooms using combustion air from the equipment room.

  • Page 58: Venting The Boiler

    5.1 Venting the Boiler The boiler must be properly vented to ensure a constant supply of clean intake air and to ensure that exhaust air is properly removed from living areas. When venting the boiler, follow these DANGER guidelines: Do not install the boiler in areas with This appliance is certified as a “Category IV”...
  • Page 59 1. Measure 3.0” inches from the end of the vent CAUTION pipe, then draw a mark at that distance. Do not start the vent run with a street elbow at the vent collar. Using an elbow directly at the Mark 3.0” from collar will not allow for a tight seal between the the end of the pipe appliances and vent pipe.

  • Page 60: About The Vent Installation Detector

    Purpose DANGER The VID’s purpose is to guide the installer to fully insert the vent pipe to a depth of at least 3.0 inches If the connections leak, harmful flue gas may or 76 mm, into the collar. If the vent pipe is not cause personal injury or death.
  • Page 61 WARNING WARNING The failure to properly install the vent pipe ● into the boiler collar or using incorrectly The vent installation sized vent pipe materials in strict compliance detector with installation instructions may cause the vent pipe to separate from the boiler which will result in excessive carbon monoxide Detectable emissions...

  • Page 62: Selecting A Vent Type

    5.3 Selecting a Vent Type All Navien boilers are Category IV appliances and prepared at the factory to be direct vented (sealed combustion). Navien recommends direct air vent installations whenever possible to avoid back drafting cold air through the boiler unit. If you cannot use a direct vent, ensure that an ample supply of make-up air is available in the installation location.
  • Page 63 Navien warranty. If there is any question about the possibility of back drafting in the installation location, use a direct venting system for the boiler.
  • Page 64 2. Provide two openings to allow for circulation of combustion air as specified by ANSI Z223.1/NFPA 54 or check local codes for the proper combustion air requirements in your region. Outdoor make up air is provided, a Indoor make up air is provided, a Maximum minimum free area of 1 in minimum free area of 1 in...
  • Page 65 Canadian Non- US Non-Direct Vent Description Direct Vent Installations Installations Clearance to unventilated soffit Clearance to outside corner Clearance to inside corner 36 in (91 cm) within a Clearance to each side of center line extended above height 15 ft (4.57 m) meter/regulator assembly above the meter/ regulator assembly...

  • Page 66: Selecting Vent Pipe Materials

    5.4 Selecting Vent Pipe Materials When you set PCB DIP switch 2 #8 to Note On, ensure that CPVC, polypropylene or stainless steel piping is used for Venting requirements differ in the US and Canada. exhaust venting. Consult the following chart or the most recent edition of ANSI Z223.1/NFPA 54 or CAN/CGA B149.1, as well as all applicable local codes and regulations when selecting vent pipe materials.

  • Page 67: Measuring Vent Length

    5.5 Measuring Vent Length Hart & Cooley Polyflue™ SW (Rigid) 2PF-xx (2”) or 3PF-xx (3”) The maximum vent length when using 2 in exhaust Z-Flex Z-DENS SW (Rigid) ducts is 65 ft (20 m). The maximum vent length 2ZDP___ (2” or 3”) when using 3 in vent ducts is 150 ft (45 m).

  • Page 68: Terminating The Vent

    5.6 Terminating the Vent Hart & Cooley Polyflue™ 2PF-90 or 3PF-90 (2” or 3” 90° Elbow) 2PF-45 or 3PF-45 (2” or 3” 45° Elbow) Before installing the boiler, determine what type of 2PF-T or 3PF-T (2” or 3” Tee) vent termination is appropriate for the installation 2PF-HVST or 3PF-HVST (2”...
  • Page 69 Indoor Boiler Installation Venting Exhaust Gas Examples The following are some possible indoor venting options: Intake Air Two-Pipe Sidewall Venting ● Intake Air Exhaust Gas Two-Pipe Snorkel Sidewall Venting * Clearance above highest anticipated snow level or grade, or as required by local codes, whichever is greater.
  • Page 70 Concentric Sidewall Venting * IPEX and Centrotherm Low Profile terminations ● only Combustion Air ** Clearance above highest anticipated snow level or grade, or as required by local codes, whichever Combustion Air is greater Vent Vent Only the following orientations are 1"...
  • Page 71 Model Type Vent Dia. Centrotherm Duravent Duravent Innoflue Flex* Polypro Flex* FasNSeal** 2 in 35 ft 35 ft NCB-190/060H NCB-190/080H 3 in 100 ft NCB-240/110H 2 in 35 ft NCB-240/130H 3 in 100 ft NCB-250/150H Only the flexible vent models listed above are approved for use with this appliance.

  • Page 72: Setting The Dip Switches

    6. Setting the DIP Switches 6.2 Dip Switch 2 (8 switch unit) CAUTION The DIP SW 2 on the circuit board configures the gas type, temperature control modes, country, and Do not remove the front cover unless ● enables or disables the space heating thermostat. the power to the boiler is turned off or disconnected.
  • Page 73 When PCB DIP switch 2 #8 is set to Note ● On, ensure that CPVC, polypropylene, or stainless steel is used for exhaust venting. This unit may be installed at elevations ● up to 10,100 ft (3,078 m) for use with natural gas and propane.

  • Page 74: Connecting The Power Supply

    Doing so will damage the boiler and void the warranty. Label all wires before disconnecting them All the Navien NCB-H boilers are supplied with a when you work on the controls. Wiring errors ● factory-installed, 3-pronged (grounded) plug. The can cause improper and dangerous operation.

  • Page 75: Installing A Cascade System

    Follow all applicable regulations when installing a cascade system. You can connect up to 1 combi-boiler and 15 Navien water heaters (NPE-A2 or NPE-S2 model) to meet high- volume water heating demands. Some possible connection options include the following:...
  • Page 76 System application drawings are The recommended recirculation Note Note ● ● intended to explain the system piping flow rate for each water heater is 2-4 concept only. GPM. Depending on the number of water heaters and the diameter Install a NaviClean Filter in the system ●...
  • Page 77 8.1.1 Piping Sizes and Considerations When plumbing a cascading system, consider the following pipe diameters and flow rates. Note that flow rates above 6.6 ft/s may cause pipe erosion. These specifications may vary depending on installation conditions. Piping Sizes for an NCB-H Boiler with up to 15 NPE-240A2 or NPE-240S2 Water Heaters Model ΔT=54°F Flow rate Water Velocity...

  • Page 78: Cascade System - Recirculation System Application Example

    8.2 Cascade System - Recirculation System Application Example When using the cascade system, external recirculation can only be connected to and controlled by the NPE “A2” water heater. Set each individual water heater to the appropriate recirculation mode utilizing the 2-way valve and front panel settings.
  • Page 79 If Recirculation Return Line Is Not Installed Install a NaviCirc valve at the furthest fixture from the water heaters as illustrated below and set the internal 2-way valve on the 1st NPE “A2” unit to the “Ext” position. Refer to the NaviCirc and NPE-A2 Installation Manuals for additional details.

  • Page 80: Connecting The Communication Cables

    You can connect one NCB-H boiler with up to 15 boilers using the Power button ( Navien water heaters (NPE-A2 or NPE-S2 Model), using the Ready-Link communication cables. Select To configure the communication settings: the NCB-H series combi-boiler in the cascading 1.
  • Page 81 3. On the sub NPE-A2 water heater panel, press To add additional sub water heater Note ● and hold the OK button ( ) for 3 seconds on at a later time, repeat step 3. the sub unit. Then, the ID 1. Allocated! message To cancel the cascade ●...

  • Page 82: Installing A Common Vent System

    9.1 About the Common Vent 9.1.1 Guidelines for a Common Vent System System The Navien Common Vent System* provides an easy way to install the vent system for an NCB-H boiler CAUTION unit and up to 7 NPE water heater units. By sharing...
  • Page 83 Adequate Installation Clearances To avoid moisture and frost build-up and to ● maintain clearances to openings on adjacent homes, 45° elbows, 90° elbows, or tees may be attached to the end of the termination vent pipe CAUTION to direct the exhaust plumes away from buildings, as long as the total allowable vent lengths, Do not install the boiler on carpeting.
  • Page 84 Clean, Debris and Chemical-free Cutting and Assembling Common Vent Combustion Air System Components Do not install the boiler in areas where dust and ● Standard tools are suitable for the cutting and debris may accumulate or where hair sprays, assembly of common vent system components. spray detergents, chlorine, or similar chemicals Follow the guidelines listed below when working are used.
  • Page 85 Vent Pipe Pitch and Supports Use approved solvent type cement Note ● for the proper vent materials. For horizontal runs, slope the horizontal section Use solvent type cement only. ● upward toward the vent termination at a rate of ” Check the date of manufacture ●...
  • Page 86 9.1.2 Determining the Length of a Common Vent Length Table Common Vent System [Total Length (L) = W + H] Follow the instructions listed below to determine the length of a common vent. Vent Lengths for an NCB-H Boiler with up to 1.

  • Page 87: Navien Common Vent Collar Kit (Back-Draft Damper)

    (Direct Vent Only) The following illustration depicts an example of a Common Vent Collar common vent system installed for a cascade system of 1 combi-boiler (NCB-H Model) and 7 Navien water heaters (NPE Model). Con den sing Wat Co m m...

  • Page 88: Starting The Common Vent System

    Maintenance Port 9.3 Starting the Common Vent System Navien Common Vent Collar Kit has a maintenance port to allow you to easily inspect the operating condition of the damper plate. 9.3.1 Common Vent Collar Kit Assembly Follow the instructions below to assemble the Common Vent Collar Kit on the NCB-H boiler unit: 1.
  • Page 89 9.3.2 Connecting the Pipe to the 4. Tighten the four mounting screws to secure the Common Vent Collar Kit in place. The screws Common Vent Collar Kit (x 4) are supplied with the Common Vent Collar Kit. WARNING Ensure that the vent pipe is properly beveled prior to installation and that the pipe is fully connected to the exhaust gas vent fitting.
  • Page 90 2. Assemble the wye joint or wye assembly to the vent pipe. Apply solvent cement to the mating CAUTION surfaces. Do not start the vent run with a street elbow at the vent collar. Using a street elbow directly at the collar will not allow for a tight seal between the appliance and vent pipe.

  • Page 91: Connecting And Terminating The Vent Pipe

    9.4 Connecting and Terminating the Vent Pipe Refer to the following example to install the common vent system. The installation area should be measured to ensure that sufficient space is available to install the boiler units and the common vent system. Ensure that the common vent system is installed near the boiler units while satisfying all clearance requirements that are specified in this manual as well as the Installation Manuals supplied with the boiler units.

  • Page 92: Setting Up The Common Vent System

    9.5 Setting Up the Common Vent 9.6 Common Vent Termination System Clearances Refer to the following figures when setting the common vent type. 9.6.1 Direct Vent Application – Vertical Installation To view and configure the cascade settings, press the Back button ( ) and the Menu button ( simultaneously for 3 seconds, and then select “4.

  • Page 93: Installing A Condensate Drain

    9.6.3 Direct Vent Application – The illustration is intended for Note ● reference purposes only. Horizontal Installation Direct the exhaust away from any ● building openings. i n . m ) m During cold weather situations, the ● 0 0 m 1 2 "...
  • Page 94 To install a condensate drain to the cascade system: 1. Form a loop with a drain hose and fix it with a tie. While shaping the hose, do not Note ● bend the hose excessively. The hose will be deformed and the flow will be restricted if the hose is bent in sharp angles.

  • Page 95: Exhaust Vent Termination Clearances (For Direct Vent)

    9.8 Exhaust Vent Termination Clearances (For Direct Vent) Inside corner detail REGULATOR VENT OUTLET In the event no regulator Legend: is present, H and I can be disregarded. = Vent Terminal = Air Supply Inlet = Area where terminal is not permitted Ref Description Canadian installations US installations...
  • Page 96 Ref Description Canadian installations US installations 6 in (15 cm) for appliances ≤ 6 in (15 cm) for appliances ≤ ● ● 10,000 Btuh (3 kW), 10,000 Btuh (3 kW), Clearance to nonmechanical air 12 in (30 cm) for appliances 9 in (23 cm) for appliances ●...

  • Page 97: Maintenance

    9.9 Maintenance 3. Reinstall the gasket and maintenance port cover, and then fix them with a set screw. Periodically check the damper condition inside the Common Vent Collar Kit through the maintenance port to ensure optimal performance of the system. Follow the instructions to check the damper condition and replace the Common Vent Collar Kit if necessary.

  • Page 98: Installation Checklist

    “Troubleshooting” in the 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.navieninc.com). Installing the boiler...
  • Page 99 Connecting the Space Heating Piping Has the system been filled (less than 30 psi) and purged of air? Does the piping incorporate means for air removal (scoop, separator, etc.)? Is there an expansion tank installed and set to the proper system pressure? If propylene glycol has been used, is it the proper type and is the concentration appropriate? If an external low water cut off (LWCO) is installed, is it wired to the boiler? Connecting a Pressure Relief Valve...
  • Page 100 Venting the boiler Is the vent termination at least 12 in (300 mm) above the exterior grade? Have you ensured that sufficient make-up air is available? Is the total vent length within the maximum vent length restriction? Connecting the Power Supply Is the supplied voltage 110-120V AC? Is the boiler plugged into a properly grounded outlet? If you have made a direct power supply connection, have you installed a power switch to...

  • Page 101: Operating The Boiler

    11. Operating the Boiler 11.1 Operating the Boiler for the First Time FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result, causing property damage, personal injury or loss of life. A.

  • Page 102: Turning The Boiler On Or Off

    11.2 Turning the Boiler On or Off WARNING To turn the boiler on or off, press the Power button ) for 0.3 seconds. Ensure that the boiler is filled with water ● before turning on the boiler for the first Before turning on the boiler for the Note time.

  • Page 103: Start-Up Wizard

    11.3 Start-Up Wizard 10. Set the Combi-Pre heat mode(Combi Pre-heat select) The setup wizard should run the first time the unit is Always On/Intelligent/Weekly ● powered on. The wizard must be completed before 11. Set the External Recirculation mode(External the boiler can be used. Recirculation select) 1.
  • Page 104 11.4.2 Adjusting the DHW Temperature 2. Press the Command dial ( ) to select the space heating temperature. The highlighted section To adjust the water temperature: will flash. 1. In normal operation mode, rotate the Command dial ( ). The space heating temperature ( ) is highlighted on the screen.

  • Page 105: Accessing Basic Menu Items

    11.5 Accessing Basic Menu Items 5. Press the Command dial ( ) to confirm the new temperature. In the Main Menu screen, you can view the boiler’s 6. Press the Back button ( ) to return to normal operating conditions, configure the space heating operation mode, or rotate the Command dial and DHW temperatures, and review error history.
  • Page 106 Item Description Item Description AHU Space Heating Set 23. Mixing valve 0 - Fully closed Temperature (°F) status If AHU is not connected, “--” ● 24. Exhaust Temp Exhaust temperature (°F) will be displayed. The temperature is Outdoor reset status (Enable ●...
  • Page 107 Time*** Default: Pump System ● Default: 0 min ● 3. Outdoor Reset Default: Disable Enable or disable heating ON/OFF zones utilizing the Navien Zone Controller. 4. Navien Zone Controller Setting range: Enabled/ ● Disabled Default: Disabled ● Operating the Boiler...
  • Page 108 Item Description CAUTION Select a heating control type. 1: Supply Temperature An outdoor sensor error may occur if the 2: Return Temperature Outdoor Reset Control mode is enabled without 3: Sys Supply Temperature the outdoor sensor installed 4: Sys Return Temperature Default: Supply ●...
  • Page 109 Combi Pre-Heat Press the Back button ( ) to return to the previous screen or menu. When using the combi pre-heat feature, you Item Description can choose commands in the menu to preheat according to the set DHW temperature. Set the hot water temperature (°F). 1.
  • Page 110 External Recirculation When Installing the Cascade System When using the External Recirculation feature, you When using the recirculation feature in the cascade can choose commands in the menu to preheat system, you can choose commands in the menu according to the set DHW temperature. to preheat according to the set DHW temperature.
  • Page 111 Set the Weekly Schedule Rotate the Command dial ( ) to switch between the list of errors. Press the Command dial ( ) to When setting up the Weekly option, select ‘Weekly, ’ select an error to view detailed information. and select between 1 Day, 3 Day, and 7 Day to go to the Schedule menu.

  • Page 112: Accessing Advanced Menu Items

    Press the Back button ( ) to return to the previous Press the Back button ( ) to return to the previous screen or menu. screen or menu. Item Description Item Description 1. SH Select a display language. View monthly space heating Operation 1.
  • Page 113 Press the Back button ( ) to return to the previous ) to switch between Rotate the Command dial ( screen or menu. the information items. Press the Command dial ( to select an item and view the information. Item Description 1.
  • Page 114 11.6.3 Setting the Operation Press the Back button ( ) to return to the previous Parameters screen or menu. To set the boiler’s operation parameters, press the Item Description Back button ( ) and the Menu button ( simultaneously for 3 seconds, and then select “3. Set the space heating supply minimum temperature.
  • Page 115 Item Description Item Description Set space heating maximum heat Set the pump freeze protection capacity limit. temperature. 8. SH Max Setting range: (Space heating Setting range: 43°F (6°C) – 50°F ● ● Limit Min capacity limit +20) % – (10°C) 100% 15.
  • Page 116 * The anti-fast cycling time is the duration that the boiler Item Description stops its space heating operation when the space heating supply or return temperatures reach the set Set the time for service notification. values for boiler operation stop temperatures. The Setting range: 30 –...
  • Page 117 Press the Back button ( ) to return to the previous Item Description screen or menu. Set the initial number of activated 3. Cascade boilers. Item Description Init-operation Setting range: 0 – 16 ● Unit To enter the Cascade Main ●...
  • Page 118 Rotate the Command dial ( ) to switch between the parameters or to increase/decrease setting values. Press the Command dial ( ) to select a parameter or to confirm after making changes. Press the Back button ( ) to return to the previous screen or menu.
  • Page 119 Item Description Item Description Test the zone 2 pump operation. Test the Mixing valve operation. Rotate the valve from its current The zone 2 pump is turned on ● position to fully open (0%), then as soon as you enter the test fully closed (100%) and then back mode.
  • Page 120 11.6.7 Setting the Special Operation 11.6.8 Operating in Air Purge Mode Modes To operate the boiler in air purge mode, press the Back button ( ) and the Menu button ( To operate the boiler in special operation modes, simultaneously for 3 seconds, and then select “8. Air press the Back button ( ) and the Menu button Purge Mode”.

  • Page 121: Understanding Error Codes

    11.7 Understanding Error Codes When an error code appears on the front panel, refer to the following chart for a definition and possible remedy for the situation. Error Code Reason Self-Diagnostic/ Action E001 Heatexchanger over temperature Reset the boiler from the front panel. E003 Ignition failure Ensure that the main gas supply valve is open.
  • Page 122 Error Code Reason Self-Diagnostic/ Action Abnormal operation: water adjustment E434 Contact technical support at 1-800-519-8794. valve E439 Abnormal operation: flow sensor Contact technical support at 1-800-519-8794. Domestic hot 2: thermistor open or short E441 Contact technical support at 1-800-519-8794. circuit E445 Abnormal operation: Bypass mixing valve Contact technical support at 1-800-519-8794.

  • Page 123: Appendixes

    For propane boilers: The propane supplier ● the instructions supplied by Navien. Gas & High mixes an odorant with the propane to make Altitude conversion using any other parts will result its presence detectable. In some instances the...
  • Page 124 Gas Orifice (Table 1) ● Gas Pressure and Conversion Kit Number Labels ● NCB-190/060H, 190/080H Orifice Identification Gas Type Altitude 0-5,399 ft 5,400-10,100 ft 0-10,100 ft Orifice...
  • Page 125 4. With the internal components exposed, locate the gas inlet pipe and the gas valve in the Location B: middle of the unit, as shown in Figure 2. Remove 4 screws here Gas Inlet Pipe Gas Valve Location A: Remove 2 screws here Figure 3.
  • Page 126 ● outlet pressure could result in damage to the valve, causing potential severe personal injury, death or substantial property damage. Navien NCB-H boilers are shipped ready to fire natural gas ONLY. GAS : NG GAS : NG GAS : LP...
  • Page 127 10. Set the PCB DIP switch to change the gas type. This unit may be installed at elevations Note ● For LP, set Dip Switch 2 #1 to ON. For NG, set DIP up to 10,100 ft (3,078 m) for use with SW2 #1 to OFF.
  • Page 128 Low fire Model Altitude Fuel Figure 8. Set Screw Location The set screw is located behind Note 0-5,399 ft the screw-on cover. This must be 10.5 10.7 NCB-190/060H removed first. NCB-190/080H 5,400- 10,100 ft 10.5 10.7 0-5,399 ft NCB-240/110H 10.5 10.7...
  • Page 129 d. Activate multiple zones and set the boiler b. Connect a manometer to the offset pressure to operate at 2-stage D. MAX mode (refer port. For dual port manometers, use the to “11.6.7 Setting the Special Operation positive pressure side. Modes“...
  • Page 130 d. At high fire, do not check the offset value and never adjust the gas valve. DANGER Improper gas valve settings can cause severe personal injury, death or substantial property damage. 13. Once the CO or offset values have been confirmed, apply the included conversion stickers to show that the appliance has been converted to Propane Gas or High Altitude.

  • Page 131: Wiring Diagram

    12.2 Wiring Diagram T/S INPUT AC24V T/S INPUT AC24V T/S INPUT AC24V T/S INPUT AC24V Outdoor **Temp Sensor System Return **Temp Sensor System Supply **Temp Sensor Appendixes...

  • Page 132: Ladder Diagram

    12.3 Ladder Diagram AC INPUT(AC 120V) AC INPUT(AC 120 V) LIVE NEUTRAL LIVE NEUTRAL Terminal Board Relay 1 FILTER Recirculation Pump Relay 2 Dual Venturi Relay 6 Boiler Pump Relay 7 Relay 3 Ignitor ZONE1 Pump Relay 4 Relay 8 3-Way Valve ZONE2 Pump Relay 5...

  • Page 133: Outdoor Temperature Sensor

    Navien Outdoor Temperature Sensor Kit operation mode. It does not work when the boiler is running in either the Minimum (MIN) or Maximum (MAX) Outdoor Temperature Sensor mode, or when the boiler’s front panel...
  • Page 134 Outdoor Outdoor High MIN Low MIN °F °C Absolute High Mass Radiant Low Mass Radiant Cast Iron Baseboard Custom Radiator Finned Tube Baseboard Fan Coil Absolute °F 113 104 95 86 77 68 59 50 32 23 14 -4 -13 °C 45 40 35 30...

  • Page 135: Component Assembly Diagrams And Parts Lists

    12.6 Component Assembly Diagrams and Parts Lists 12.6.1 Case Assembly Appendixes...
  • Page 136 Description Part # Remark Base 20049684A Base Bracket 20007609A Base Lower Bracket 20007643B Pump Bracket Ass'y 30024919A Screw (M4X10L) 20049000A Main PCB 30025359A Terminal PCB 30019951A Intake Air Duct Assembly 30008662B Intake Air Filter 30016248B 30021100A Air Vent Adapter 20051293A Rubber Ring 20041970A Exhaust Duct Assembly...
  • Page 137 12.6.2 Burner Assembly 24 6 Appendixes...
  • Page 138 Description Part # Remark Damper 30008825A O-Ring (G50) 20003019A Pan Bracket 20022095A Siphon 30024911A 20022750B NCB-190/080H Mixer Chamber 20022751C NCB-250/150H Ignition Transformer 30026063A 20021677A NCB-190/080H Burner Packing 20021672A NCB-250/150H 30025588A NCB-190/080H Heat Exchanger Ass;y 30025587A NCB-250/150H Thermistor (Exhaust) 30009478A Thermistor (Water) 30008366A High Limit Switch 30023954A...
  • Page 139 12.6.3 Waterway Assembly 24 10 Description Part # Remark 30024107A 18EA Plate Heat Exchanger 30021098B 24EA Mixing Valve Adapter 20044471A 20017744A Mixing Connector 20044469A Flow Adjust Valve 30008247A DHW Inlet Connection Adapter 20044470A Taptite Screw (Φ4×6) 20017962A DHW Temperature Sensor (Blue) 30022207B DHW Inlet Connection Adapter 20044477A...
  • Page 140 Description Part # Remark Fastener (27) 20017726A Fastener (36) 20017724A Fastener (19.7) 20007733B O-Ring(P14, WRAS) 20048004A O-Ring(P16, WRAS) 20048005A O-Ring(P18, WRAS) 20048006A O-Ring(P26) 20032409A O-Ring(P28) 20022142A Screw (M4×10) 20038757A Filter Frame 20033618A Filter Mesh 20033617A O-Ring (P25) 20032528A Mixing Valve Manifold 20044482B DHW Temperature Sensor (Red) 30023765A...
  • Page 141 12.6.4 Fan (Gas) Assembly Appendixes...
  • Page 142 Description Part # Remark Fan Assembly 30025295A Fan Packing 20022744A O-Ring (G75) 20018079A 30024967A NCB-190/080H Dual Venturi 30025251A NCB-250/150H 20031242A NCB-190/080H Silence 20032570A NCB-250/150H 20049499A NCB-190/080H Silence Adapter 20032569A NCB-250/150H Venturi Packing 20022660A 20049500A NCB-190/080H (NG) 20049501A NCB-250/150H (NG) Gas Ofifice 20050545A NCB-190/080H (LP) 20050546A...
  • Page 143 Memo...
  • Page 145 Installation & Operation Manual NCB-H Condensing Combi-Boilers 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.navieninc.com. ● For warranty service, always contact Technical Support first. ● Contact the technician or professional who installed your boiler.

This manual is also suitable for:

Ncb-190/080hNcb-240/110hNcb-240/130hNcb-250/150h

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