Navien CH-180 Service Manual
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Navien CH-180 Service Manual

Navien CH-180 Service Manual

Combination water heater / heating boiler
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See also: Operating Manual , User's Operation Manual
Service Manual Service Manual
Combination Water Heater / Heating Boiler
TEL +949-420-0420 FAX +949-420-0430
Ver. 1.00
Navien America, Inc.
20 Goodyear lrvine, CA 92618
www.naviennamerica.com
MODEL
CH-180
CH-240 ASME
WARNING
If the information in this manual is not followed exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
- 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.
1
st
Edition - July 2010
No. 20A-GT-002
Service Manual
Combination Water Heater
/ Heating Boiler
CH-210
CH-240

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  • Page 1 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. Navien America, Inc. 20 Goodyear lrvine, CA 92618 Edition - July 2010 TEL +949-420-0420 FAX +949-420-0430 No.

  • Page 3: Table Of Contents

    4.4. WIRING DIAGRAM 4.5. ELECTRICAL DIAGNOSTIC POINTS 4.6. KEY COMPONENTS DESCRIPTION 4.6.1. 4.6.2. Thermal Fuse 4.6.3. Transformer 4.6.4. High Limit Switch or Exhaust Limit Switch 4.6.5. Thermistor 4.6.6. Fan motor ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 4 5.7. 06ERROR 5.8. 07ERROR 5.9. 08ERROR 5.10. 09ERROR 5.11. 10ERROR 5.12. 11ERROR 5.13. 12ERROR 5.13. 13ERROR 5.15. 15ERROR 5.16. 16ERROR 5.17. 18ERROR 5.18. 19ERROR 5.19. 21ERROR 5.20. 22ERROR 5.21. 27ERROR ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 5 8.2.5. Flame Rod 8.2.6. Ignition Transformer 8.2.7. APS 8.2.8. Manifold 8.2.9. Main Gas Valve 8.2.10. GPS 8.2.11. Condensation Trap 8.2.12. Flow Sensor 8.2.13. Circulation Pump 8.2.14. 3-way Valve 8.2.15. Water Pressure Sensor ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 6 8.2.19. Domestic Hot Water Outlet Collar 9. COMPONENTS DIAGRAM AND PART LIST 9.1. CASE DISASSEMBLE 9.2. BURNER DISASSEMBLE 9.3. WATER WAY DISASSEMBLE INSPECTION AND MAINTENANCE SCHEDULE 10.1. ANNUAL SERVICING 10.2. INSPECTION REPORT 10.3. MAINTENANCE REPORT ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 7: Revisions

    Revisions Version Description of changes Date 1.00 First Issue July/30/10 ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 8: Navien Warranty

    / boiler and its component parts to be free from defects in materials and workmanship, under normal use and service, for the Applicable Warranty Period. At its option, Navien will replace the defective component part(s), in accordance with the terms of this Limited Warranty, if it fails in normal use and service during the Applicable Warranty Period.
  • Page 9 One (1) year from the Effective Date. The payment and amount of any payment are subject to approval at Naiven’s sole discretion. The Labor Allowance will be paid based on Navien’s Schedule of Labor Allowances. TRANSFERABILITY This warranty is offered to the original and subsequent owners of the combination water heater / boiler but is limited to the original address registered with the warranty only.

  • Page 10: Handling Of This Manual

    • Navien America Inc. reserves all rights related to this manual • This manual should be accessible only to technical service personal authorized by Navien America Inc. • Read and understand the safety information before operating or servicing this Navien Boiler. About Notation in the Manual Indication of Refer To The “...

  • Page 11: Abbreviation And Definition

    Abbreviation and definition Abbreviation Description of changes General name of CH-180, CH-210, and CH-240 and CH-240 ASME Natural Gas Liquid Gas Air Pressure Air Pressure Sensor Domestic Hot Water Fan Motor GARC Gas Air Ratio Control Gallon per Minute Gas Pressure Sensor...

  • Page 12: Safety Considerations

    IMPORTANT Warns of a risk of material loss and environmental pollution. Indicates additional information that is important but not related to NOTE personal injury or property damage. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 13: Safety Precautions

    Keep flammable products: far away from heater in approved containers, tightly closed, andout of children’s reach. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 14 If the proposed boiler outlet temperature is above 125 , a thermostatically controlled mixing valve or temperature limiting valve should be considered to reduce the risk of scalding. Contact a licensed plumber or the local plumbing authority for further information. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 15 • Immediately call your gas supplier from the outside of the building. Follow the gas supplier’s instructions. • If you cannot reach your gas supplier, call the fire department. • Notify your plumbing/ heating contractor from the outside of the building. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 16 • Installation condition may affect the servicing. Read all related information in the “Installation manual” and the “User’s Operation Manual”. • The Navien Boilers must be installed according to all local and state codes or, in the absence of local and state codes, the most recent edition of the “National Fuel Gas Code (ANSI Z223.1/NFPA 54)”...
  • Page 17 WARNING GAS TYPE and AC VOLTAGE Navien units come from the factory configured for use with either Liquid Propane (LP) or Natural Gas (NG). Before starting the servicing, check the rating plate located on the side of the Boiler to ensure the unit matches gas type, gas pressure, water pressure and electrical supply.

  • Page 18: Product Information

    2. Product Information 2.1. Product Information KD Navien condensing gas boiler is a fully automatic, wall hung, fan assisted balanced flue condensing boiler for use with Natural Gas and Liquid Propane Gas. This appliance is fully modulating and provides central heating and domestic hot water.

  • Page 19: Layout And Key Components

    PCB Board NACR1GS32301 Ignition Transformer BH1201045A DHW Cold Water BH2507396A Air Pressure Sensor NASS9EX00009 Inlet Adaptor Auto Feeder Valve BH0904011A Exhaust Duct BH2544007D Main Gas Valve BH0901018A Exhaust Pipe BH2505401B ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 20: Technical Data

    Flame Rod, Overheat Cut-off Device, Ignition Operation Detector, Safety Devices Water Temperature High Limit Switch, Exhaust Temperature High Limit Switch Plumb Easy Valve Set, Outdoor Sensor, Pressure Relief Valve, Accessories Condensate Neutralizer, Communication Cable ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 21: Dimensions

    A. Connection Diameter Description Diameter 3” Exhaust Air lntake 3” Heating Supply 1” Connection Heating Return 1” Connection Hot Water Outlet 3/4” Cold Water lnlet 3/4” 3/4” Gas lnlet Auto Feeder 1/2” ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 22: System Details

    This control enables the user to either set the desired room temperature or set the heating water temperature. In some cases this thermostat may not be suitable for multi-system applications. (The installing contractor will make this determination and install suitable alternative controls.) ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 23: Domestic Hot Water Mode

    4.1.2. Domestic Hot Water Mode The domestic hot-water (DHW) is controlled by the user. Because the Navien Combination Boiler is a multi-purpose design, it can provide hot water on demand. Navien Combination Boiler will produce hot water only when you use it.

  • Page 24: Operation Flow Chart

    Burner Start-up Igniter OFF? Lock-out: GV/lgniter Power 004E Flow Sensor >=0.53 GPM Lock-out: Igniter ON 015E Igniter ON Lock-out: for 1sec? 027E Lock-out: 009E Igniter OFF Lock-out: 010E FM Control normal? ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 25 Flame OFF straight 20 times during Flame OFF? 012E burner operation? Lock-out: FM rpm<= 400? 009E Lock-out: Excess Air Pressure? 010E Lock-out: APS normal? 027E Lock-out: GPS normal? 035E GARC ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 26 CH : 3- WAY Valve Off DHW : 3-WAY Valve On Heat Demand? CH : 3-WAY Valve Off CH : 3-WAY Valve Off Post-Purge : Fan & Pump ON for 3 min Pump On ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 27 030E Open? Lock-out: Supply Thermistor 005E <= 14 °F Lock-out: Supply Thermistor 006E >= 248 °F Lock-out: Return Thermistor 018E <= 14 °F Lock-out: Return Thermistor 019E >= 248 °F ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 28: Dip Switch Settings

    #1 & 2: Burner Operation Mode Select DIP Switch Operation Mode Normal Operation Maximum Operation Minimum Operation 3 Stage Minimum #1 & 2: Burner Operation Mode Select DIP S/W Model CH-180 CH-210 CH-240, CH-240 ASME ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 29 Temperature Control Space Heating Temperature 1 Refer to next page (#4 & 5) Space Heating Temperature 2 DHW Temperature 1 Refer to next page (#7 & 8) DHW Temperature 2 ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 30 The dip switch 7(to the right of the set of 8), which is used only for organizing cascade system, should be switched ON if the corresponding unit is the first or the last unit of cascade connection. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 31: Wiring Diagram

    4.4. Wiring Diagram ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 32: Electrical Diagnostic Points

    4.5. Electrical Diagnostic Points ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 33 GPS operating. Confirm if voltage flows without any DC 15V BLACK-YELLOW relations with the GPS operating. DC Fan Voltage changes as the fan DC 0~7.5V BLACK-ORANGE operating Check PULSE. BLACK-WHITE 0rpm~6500rpm ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 34 AC 24V input On/Off, Else dry contact input On/Off. If AC 24V is connected externally Externally AC 24V output On/Off. Extern ON : AC 97~138V Confirm voltage as operating. Power OFF : 0V ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 35: Key Components Description

    Board failure, the whole unit does not operate at all. Error Code E015 1. Visual inspection: Connection and/or breakage of wires and/or burn Diagnostic marks on the PCB Board. Color / Number of wires ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 36: Thermal Fuse

    120VAC power supply; therefore, the unit comes equipped with this transformer. Error Code 1. Visual inspection: Connection and/or breakage of wires. Diagnostic 2. Voltage check: Check range of voltage shown below. Color / Black - Black Number of wires ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 37: Transformer

    3. [AC 19 V] Blue – Blue : AC 16~24 V Number of wires 4. [Power trans AC 150 V] Red – Red : AC 123~177 V 5. [Power trans AC 120 V] White – Black : AC 97~138 V ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 38: High Limit Switch Or Exhaust Limit Switch

    2. Voltage check: Check range of voltage shown below. Color / 1. Yellow – Yellow : DC 4 ~ 6 V Number of wires 2. Red – Red : DC 4 ~ 6 V ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 39: Thermistor

    4. Yellow – Yellow : DC 0 ~ 5 V 5. Resistance-Open=infinite; Shorted=0 Nomal =4.121 at 113 Wire Color Wire Color : Black : Blue Wire Color Wire Colo : Red : Yellow ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 40: Fan Motor

    1. Black-Red : DC 127 ~ 184 V Color / 2. Black-Yellow : DC 15 V Number of wires 3. Black-Orange : DC 0~7.5 V 4. Black-White : 0 ~ 6,500 RPM ? 3.4" (? ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 41: Flame Rod Ass'y

    2. No effects on the unit, however, the durability of the igniter wears down Error Code E003, E004 Diagnostic 1. Visual inspection: Connection and/or breakage of wires. Color / Number of wires Bracket Flame rod wire Insulator (Ceramic) Igniter Flame rod ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 42: Ignition Transformer

    2. Voltage check: Check range of voltage shown below. Color / Blue – Blue : On : AC 97 ~ 138 V Number of wires Off : 0 V Input Voltage Output Voltage Output Current 115V,60Hz 19KV±2KV 10mA±2mA ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 43: Aps

    2. Voltage check: Check range of voltage shown below. Color / 1. Red- black : DC 5 V Number of wires 2. White – black : DC 0.3 ~ 4.5 V ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 44: Manifold

    1. Yellow – Yellow : On : DC 83 ~ 120 V, Off : 0 V Number of wires 2. Red – Red : On : DC 83 ~ 120 V, Off : 0 V ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 45: Main Gas Valve

    2. Yellow - yellow : ON – DC83 ~ 120 V, OFF – 0 V Number of wires 3. Red – red : ON – DC83 ~ 120 V, OFF – 0 V ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 46: Gps

    2. Voltage check: Check range of voltage shown below. Color / 1. Red- black : DC 5 V Number of wires 2. White – black : DC 0.3 ~ 4.5 V ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 47: Burner

    Diagnostic unstable flame conditions during operation. Color / Number of wires 1-Stage Burner 2-Stage Burner 3-Stage Burner Burner Body (Fuel Gas + Combustion Air Combustion Air Supply Fuel Gas Supply ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 48: Flow Sensor

    3. Open/drain and verify that impellor spins freely Color / 1. Red- black : DC 5 V Number of wires 2. White – black : DC 0.3 ~ 4.5 V Water Outlet Water Outlet ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 49: Primary Heat Exchanger

    E001, E016, E030, E037 1. Visual inspection: check if there is a crack on the surface of heat exchanger. Diagnostic 2. Sound inspection: check if there’s boiling noise. Color / Number of wires ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 50: Secondary Heat Exchanger

    E001, E016, E030, E037 1. Visual inspection: check if there is a crack on the surface of heat exchanger. Diagnostic 2. Sound inspection: check if there’s boiling noise. Color / Number of wires ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 51: Dhw Heat Exchanger

    Diagnostic Leak in plate heat exchanger will cause pressure in space heating side to increase to tap water pressure level. Color / Number of wires ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 52: Circulation Pump

    2. Voltage check: Check range of voltage shown below. Color / 1. Brown-White : ON AC 97 ~ 138 V, OFF 0 V Number of wires 2. Brown-black : ON AC 97 ~ 138 V, OFF 0 V ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 53: 3-Way Valve

    2. Voltage check: Check range of voltage shown below. Color / Blue-Black : ON AC 97 ~ 138 V, OFF 0 V Number of wires Confirm voltage as the 3-Way Valve operating ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 54: Water Pressure Sensor

    E02, E11, E13 1. Visual inspection: check the circulation pump connection wire. Diagnostic 2. Voltage check: Check range of voltage shown below. Color / 1. Black-Red : DC 0~5V Number of wires ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 55: Auto Feeder Valve

    1. Visual inspection: check the Auto feeder valve connection wire. Diagnostic 2. Voltage check: Check range of voltage shown below. Color / Blue-Blue : ON AC 97 ~ 138 V, OFF 0 V Number of wires ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 56: Troubleshooting

    5. Clean flame rod 1. Check the pump E013 Abnormal pump Manual 2. Remove air from the pipe 1. Check power supply E015 Abnormal control board Manual 2. Check the Emergency Switch ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 57 2. Check hose connection E035 Manual gas pressure sensor 3. Replace GPS. Automatic E036 Communication failure 1. Contact to Navien tech. dept. Abnormal the Water 1. Check the water flow sensor. E039 Manual Flow Senor Outdoor: 1. Check the Thermistor...

  • Page 58: 01Error

    Resistance between two red wires of CN 13 is from 0.8 to 20k ohm at normal condition Caution: Before measuring resistance of the Check unit thermistor, remove the connector from the PCB. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 59 2. If the 01 Error occurs when hot water is used only, check if the heat hot water heat exchanger is clogged. exchanger is clogged. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 60 Sudden increase of temperature due to PCB DIP S/W model setting setting error or max setting. Other trouble If the trouble continues despite the checking of above items, Defective replace the PCB. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 61: 02Error

    3. Check if water leaks from the heating pipe. Leaking in unit? Check in unit (Leaking?) Auto feeder valve Open? Check the Auto feeder v/v Check DHW cold water Normal Pressure? Pressure Normal state ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 62 Frequent water filling can occur due to leakage of pipe. Check the Frequent leakage on the pipe connector and distributor. Check if the water Pipe leaks level becomes lower through the expansion tank, and give the explanation to the customer. (28E) ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 63: 03Error

    10. Disassemble the manifold and check the nozzle. 11. Check the flue and air supply (downward installation / rainwater collected) 12. If the trouble continues despite the checking of above items, replace the PCB. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 64 Check whether ground circuit is device normally detected? properly installed. operating? Check the current of CN 19:7-20μA Check the voltage between two wires of CN 19: 10-20VDC Try to restart Replace PCB ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 65 Check the voltage between two wires of CN 14:2 - 10VDC Is the tube which is connected with modulating Check tube gas valve properly installed? Check the flame rod Check the burner assembly ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 66 An ignition failure may occur due to improper gap, while gap and discharge seems normal when checked via the flame monitoring shape window. Therefore, it is required to check the gap after disassembly. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 67 2. Replace the PCB if power is not supplied. valve 3. If power supply is normal, check if the coil is open. 4. Check if the solenoid valve works properly. Feel or hear a click. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 68 2. Check if the hose is clogged with water remained from installa noise tion. occurs at ignition The system works but combustion is not normal due to the defective APS. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 69 <Check the differen-tial gas pressure> Check if there is any Ignition failure occurs if there is debris in the nozzle. debris in the Disassemble the manifold and check the nozzle (Stage 1). nozzle. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 70 Defective air Check if rainwater is collected due to downward air intake. air supply supply If the trouble continues despite the checking of above items, Defective Other trouble replace the PCB. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 71: 04Error

    Clean or replace flame rod during no burner operation? Check the current of CN 19: 7 - 20μA Check the voltage between two wires of CN 19: 10-20VDC Replace PCB ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 72 If gas leaks, close the main gas valve and repair the unit before using the system. Other If the trouble continues despite the checking of above items, Defective trouble replace the PCB. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 73: 05Error

    1. Measure the resistance of the temperature sensor. sen-sor 2. If the resistance is abnormal, replace the temperature sensor. Defective Other If the trouble continues despite the checking of above items, replace the PCB. trouble ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 74: 06Error

    Measure the temperature sensor resistance, if the value is 0Ω, sensor replace the temperature sensor Defective Other If the trouble continues despite the checking of above items, replace the PCB. trouble ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 75: 07Error

    1. Measure the resistance of the temperature sensor. 2. If the resistance is abnormal, replace the temperature sensor. sensor Other If the trouble continues despite the checking of above items, Defective replace the PCB. trouble ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 76: 08Error

    Measure the temperature sensor resistance, if the value is 0Ω, replace the temperature sensor sensor Other If the trouble continues despite the checking of above items, Defective replace the PCB. trouble ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 77: 09Error

    5. If the blower connector is wet due to any reason including leakage, take the corrective action. 6. Check for loose connection of white tower on PCB ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 78 CN 8: 120 - 180VDC Is there any pulse output from Replace fan assembly the fan motor? Check the voltage between black and white wire of CN 8: 2 - 8VDC Replace PCB ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 79 2. If RPM is low or there is a sensor circuit error, replace the Blower blower. rotator RPM error 3. If the trouble continues despite the checking of above items, replace the PCB. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 80: 10Error

    5. Check if the air supply/exhaust flue is clogged (rainwater collected due to dent or downward installation). 6. Check the flue environment (inflow of exhaust gas). 7. Defective air pressure sensor or PCB. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 81 Blow air with mouth through the air pressure hose. error clogged 3. Check if the air pressure hose is torn. Increased RPM may cause blowout and noise. 03E can occur due to the same trouble. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 82 Air pressure If the same trouble continues after reviewing of the above items, Detection sensor 1. replace the air pressure sensor, or error 2. replace the PCB. controller ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 83: 11Error

    Check if the safety valve is stuck. Defective water 1. Check if the water pressure sensor is frozen during the winter. E11 + SEE pressure 2. Replace the defective or opened water pressure sensor. sensor ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 84: 12Error

    Does the water heater have Check the gas pressure sufficient gas pressure? Gas Pressure NG : 6”~10.5” w.c LP : 8”~13.5” w.c Check the burner assembly, flame rod and gas valve assembly ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 85 Low gas pressure causes blowout of flame. and noise main gas valve Thick flame causes noise and accidental fire. Other If the trouble continues despite the checking of above items, replace the PCB. trouble ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 86: 13Error

    During pump operating, Repeat pump on and off Remove air from pipe does water pressure increase N times, if N < 5? higher than 3.0 Psi. Normal state ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 87 The pump The pump can be temporarily stuck due to contaminated heating Debris in the water. is restarted heating water Replace the pump after cleaning the heating pipe. normally ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 88: 15Error

    Power supply Power supply grounding noise causes malfunction. Disconnect ground by applying a tape on the grounding grounding terminal in the receptacle, and check if the PCB works normally. noise ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 89: 16Error

    Check the resistance between two white wires of CN 13: short-circuit (016E) Check the resistance between two brown wires of CN 13: short-circuit (030E) Caution: Measuring should be done at least 30 minutes after error. Replace PCB ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 90 Check, with a multi-tester, if the thermal fuse is Abnormal The thermal disconnected. safety fuse is If the fuse is disconnected, replace the part and device disconected. check the cause of cutoff. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 91 The surface temperature rises due to defective heat exchanger. exchanger Other Replace the heat exchanger. overheated trouble If the trouble continues despite the checking of above Defective items, replace the PCB. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 92: 18Error

    Resistance between two black wires of CN 13 is from 0.8 to 20KO at normal condition. Caution: Before measuring resistance of the thermistor, remove the connector form the PCB. Check connector ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 93 If the same phenomenon, replace the thermistor. Defective If the trouble continues despite the checking of above Other items, replace the PCB. trouble MΩ Open <Check if the thermistor is open> ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 94: 19Error

    Resistance between two black wires of CN 13 is from 0.8 to 20KO at normal condition. Caution: Before measuring resistance of the thermistor, remove the connector form the PCB. Check connector ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 95 If the same phenomenon, replace the thermistor. Defective Other If the trouble continues despite the checking of above items, replace the PCB. trouble 0kΩ Defect < Check short-circuit of the space heating return thermistor> ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 96: 21Error

    Resistance between two blue wires of CN 13 is from 0.8 to 20KO at normal condition. Caution: Before measuring resistance of the thermistor, remove the connector form the PCB. Check connector ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 97 Replace the cold water inlet thermistor. sensor Defective Other If the trouble continues despite the checking of above items, replace the PCB. trouble MΩ Open < Check short-circuit of the cold water inlet thermistor > ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 98: 22Error

    Resistance between two blue wires of CN 13 is from 0.8 to 20KO at normal condition. Caution: Before measuring resistance of the thermistor, remove the connector form the PCB. Check connector ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 99 If the same phenomenon, replace the thermistor. sensor Defective Other If the trouble continues despite the checking of above items, replace the PCB. trouble <Check short-circuit of the cold water inlet thermistor> ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 100: 27Error

    During fan motor operation, is Replace APS the output voltage of APS normal ? Check the voltage between black and white wire of CN 6: 1 - 4VDC Replace PCB ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 101 An error occurs if the air pressure sensor voltage of 1.20V is detected before prepurge. Defective If the trouble continues despite the checking of above Other items, replace the PCB. trouble <Check the voltage of the air pressure sensor> ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 102: 28Error

    *AWS: Auto Water Supplement During AWS valve operation, Check*AWS valve is the output voltage of AWS or connector valve normal? Voltage between pin1 and pin3 of CN21 is 120VAC Replace main PCB ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 103 Abnormal display. sense error sense error Suspension of cold water supply or the cold water Suspension frozen. If the trouble continues despite the checking of above items, replace the PCB. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 104: 30Error

    Remove the switch and check, with a multitester, the limit switch resistance (MΩ defect). <Check the exhaust high limit switch.> Other Defective If the trouble continues despite the checking of above items, replace the PCB. trouble ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 105: 35Error

    During gas valve OFF, is the Replace GPS output voltage of GPS normal ? Check the voltage between black and white wire of CN 7: 1 - 4VDC Check connector ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 106 Check if the GPS hose is bent or torn. Defective Check the output voltage. GPS part <Check the harness.> Other Defective Check the output If the trouble continues despite the checking of above items, re-place the PCB. trouble ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 107: 36Error

    1. Check if power supply to a boiler unit is off. Check 2. Check if the communication cable is damaged or disconnected. items 3. Check if the dip switch setting is correct. 4. Check if the cascade setting is correct. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 108: 39Error

    1. Check the supply of cold water. (Frozen / locked valve) Check 2. Defective flow sensor items 3. Defective PCB. Cancelation cascade system and faucet open Water flow out? Check supply cold water Check connector Or Replace water flow sensor ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 109: 40Error

    1. Check if the outdoor temperature sensor is disconnected, and if the connector is connected properly. Check 2. Check if the outdoor temperature sensor is defective. items 3. Defective PCB. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 110: Troubleshooting Guide By Symptom

    Noise due to defective air pressure sensor. Replace the air pressure sensor. Noise due to torn air pressure hose. Noise during Noise may be intermittent depending on the size of the damage. combustion ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 111: Hot Water

    Check the Check if the cold water filter is clogged with debris. from the pipe faucet Check if the cold water / hot water pipes are frozen during the winter. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 112 Warm floor when valve is not switched to heating for preheating for hot Defective heating water or due to defective packing. 3-way valve function is Replace the 3-way valve. not used. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 113 Check the controller voltage of the PCB, and take the action separately for wire power wiring error and defective PCB, respectively. If the power supply is normal, replace the remote controller. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 114: Inspection

    - Digital manometer or U tube type manometer with 14 inch water column (w. c.) scale, a hose and two 1/8 inch taps - Assorted screw drivers - Leak solution or leak detector - Teflon tape ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 115: Measuring Gas Pressure Setting

    6. Open multiple fixtures that have high flow rates (bathtub, showers, kitchen sink) to ramp the boiler up to its maximum burn. 7. When the Navien boiler is at maximum burn, check the inlet gas pressure read ing on the manometer; it should read between 6.0”~10.5” W.C for Natural gas between 8.0”~13.5”...

  • Page 116: Adjusting The Gas-Air Ratio

    5. Set the DIP switches for the 3rd stage minimum operation mode (#1: ON, #2: ON). Open a hot faucet. 6. When the Navien boiler is burning at the 3rd stage minimum, check the gas-air pressure difference reading on the manometer. Compare the gas-air pressure difference with FACTORY setting chart in bottom page.
  • Page 117 CH-240 Natural Gas 0.63” ± 0.04” W.C 2.13” ± 0.08” W.C CH-240 ASME gas valve Air Pressure Gas Pressure Proportional valve Minimum Modulating PCB Board Manometer gas valve Maximum Modulating ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 118: Maintenance

    6. When the water is completely drained, return the pump drain plug and the inlet filter and close the pump drain plug inside the unit. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 119: Cleaning The Intake Air Filter

    7. Once the filter is back on the intake pipe, reset the fan back to its original posi tion. Insert the fan on an angle into the back corner of the case and then move it into its correct position, 8. Replace the screws. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 120: Replacement Of Parts

    8 ~ 10 inches long. A flashlight and magnetic tip reach are also handy. Navien recommends the use of a parts tray or bowl to hold small parts and screws. All of the hardware is essential to the proper operation of the unit upon re-assembly.

  • Page 121: Components Replacement Instructions

    12. Turn on water supply, power supply, and gas supply. 13. Perform the measuring of gas pres sure setting procedure. NOTE Connecting ports must be right color and place. Figure 2 ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 122: Fuse

    12. Turn on water supply, power supply, and gas supply. NOTE Before remove, press the part B into part C and put together as removing the capsule. Figure 4 Figure 5 ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 123: Transformer

    9. Tighten the 2 screws from power transformer. 10. Replace the PCB. (refer to 8.2.1 PCB) 11. Install front panel using 4(four) screws. 12. Turn on water supply, power supply, and gas supply. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 124: Fan Motor(Combustion Air)

    It will damage to fan housing. 2. Confirm whether the screws tighten enough or not. 3. Confirm whether there are unnec essary noises after reinstalled fan. Figure 8 ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 125: Flame Rod

    14. Turn on water supply, power supply, and gas supply. NOTE Always use factory seal packing between the electrode and burner assembly. Figure 11 8. Loosen the 2 ignition electrode screws. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 126: Ignition Transformer

    14. Turn on water supply, power supply, and gas supply. Figure 13 8. Loosen the two igniter screws. NOTE 1. Check up whether fixing exactly done. 2. Check up the connecting termi nal. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 127: Aps

    NOTE As reassemble the air pressure sensor, careful with right size and direction. Figure 16 7. Loosen the air pressure sensor low erside 2-screw from burner assemble. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 128: Manifold

    12. Attach the manifold and secured with screws. Figure 19 WARNING 7. Pull out the gas pipe. Failure to correctly assemble the components according to these instructions ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 129: Main Gas Valve

    5. Pull out the PCB. (refer to 8.2.1 lating valve. PCB) 6. Pull out the gas pipe. (refer to 8.2.8 Manifold) 7. Detach the air pressure feedback tube, gas pressure sensor tube. ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 130 11. Positioned main gas valve. 12. Attach the main gas valve and secured with screws. 13. Assemble the air pressure feedback tube, gas pressure sensor tube and wire harness connector. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 131: Gps

    2 screws from base. NOTE Always use right type of tube and right place. Figure 27 8. Remove the gas pressure sensor 2 tube into the gas pressure sensor. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 132: Condensation Trap

    1. Always make sure pin on right direction and secure. 2. When installed the condensation trap connecting hose, it should be installed from the secondary heat exchanger drain port first and then Figure 30 to trap. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 133: Flow Sensor

    12. Tighten the cold water inlet adaptor 2 screw. 13. Replace the heating water inlet pipe and fastener “C”. 14. Replace the PCB. (refer to 8.2.1 PCB) Figure 33 15. Install front panel using 4(four) screws. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 134: Circulation Pump

    14. Replace with new circulation pump. 15. Replace the stainless clip. 16. Reseat the non-threaded end of circulation pump into the stainless fitting. At this time, be watchful the black gasket ring(packing). Figure 36 ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 135: 3-Way Valve

    5. Pull out the PCB. (refer to 8.2.1 PCB) 6. Pull out the circulation pump. (refer to 8.2.13 Circulation Pump) 7. Loosen the heating water inlet pipe II screw from 3-way valve. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 136: Water Pressure Sensor

    12. Open a hot water tap and ensure sensor wire housing from the PCB. there are no leaks at the boiler. NOTE 1. Always use right part(O-ring) and right size and place to pipe Figure 42 ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 137: Space Heating Strainer (Filter Cleaning Or Strainer Replace)

    8. Open a hot water tap and ensure 5. Pull out the space heating strainer. there are no leaks at the boiler. NOTE 1. Always use right part(O-ring) and right size and place to pipe ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 138: Auto Feeder Valve

    8. Loosen the auto feeder valve adap there are no leaks at the boiler. tor 2 screw from bottom base. NOTE 1. Always use right part(O-ring) and right size and place to pipe Figure 47 ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 139: Domestic Hot Water Exchanger

    16. Install front panel using 4(four) screws. 17. Turn on water supply, power supply, and gas supply. 18. Open a hot water tap and ensure Figure 49 there are no leaks at the boiler. ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 140: Domestic Hot Water Outlet Collar

    16. Install front panel using 4(four) screws. 17. Turn on water supply, power supply, and gas supply. 18. Open a hot water tap and ensure there are no leaks at the boiler. Figure 52 ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 141: Components Diagram And Part List

    9. Components Diagram and Part List 9.1. Case Disassemble ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 142 PCB Board Bracket(Upper) BH2505413A PCB Board Bracket(Lower) BH2505414A Power Switch BH1426002A Screw D4 x 8L BH1705007A Bolt M4 x 16L BH1603009A Screw D4 x 12L BH1612005A Bolt D4 x 10L (STS) BH1611006A ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 143: Burner Disassemble

    9.2. Burner Disassemble ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 144 180 Propane GPS venturi BH2507664A 210/240 NG BH2507732A 210/240 Propane 34-1 GPS venturi tube BH2203002A Gas pressure sensor NASS9EXGPS01 GPS bracket BH2507346A Main gas valve BH0901018A Gas inlet adapter BH2507714A ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 145 Screw D4 x 14L BH1701031A Screw D4 x 14L BH1708006A Bolt M4 x 12L (STS) BH1603007A Screw D4 x 25L BH1701030A Fan Motor Damper BH2505403C O-Ring BH2421003A Screw D4 x 4L BH1710001A ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 146: Water Way Disassemble

    9.3. Water Way Disassemble ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 147 DHW Outlet Adapter BH2507558A PAS30KHE_005 DHW Heat Exchanger PAS40KHE_003 210/240 BH1301020C S/H Strainer S/H Return Pipe BH2507550A S/H Pipe 2 BH2507372B S/H Pipe 1 BH2507373A BH2501442C Siphon Siphon Hose BH2204047A ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 148 Bolt D4 x 10L (STS) BH1611006A Bolt M4 x 12L BH1612007A Screw D4 x 14L BH1701003A BH1603015A Bolt M4 x 8L H/E Packing BH2406048A O-Ring (P16) BH2422017A Fastener A BH2507400B ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 149: Inspection And Maintenance Schedule

    - Draining the boiler and cleaning the inlet water filter - Cleaning the Return Filter - Cleaning the intake air filter - Flushing the heat exchanger - Replacement of parts ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 150: Inspection Report

    YES / NO Checking Hot Water Temperature and Flow YES / NO Checking Noise YES / NO Checking Venting Systems YES / NO Checking the Remote Controller YES / NO ©Navien America Inc. 2010 CH series service Manual Version 1.0...

  • Page 151: Maintenance Report

    Draining the Boiler and Cleaning the Inlet Water Filter YES / NO Cleaning the Return Filter YES / NO Checking the Intake Air Filter YES / NO Flushing the Heat Exchanger YES / NO Replacement of Parts ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 152 Memo ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 153 Memo ©Navien America Inc. 2010 CH series service Manual Version 1.0...
  • Page 154 Memo ©Navien America Inc. 2010 CH series service Manual Version 1.0...

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