Navien NP-180 Service Manual

Nr/np series tankless gas water heater

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Operation & installation manual (89 pages)

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Table of Contents

Quick Links

Troubleshooting

Summary of Contents for Navien NP-180

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
4.1. SCHEMATIC AND FLOW DIAGRAM 4.1.1. NR-A Model 4.1.2. NP-A Model 4.1.3. NR Model 4.1.4. NP Model 4.2. OPERATION FLOW CHART 4.3. DIP SWITCH SETTINGS 4.4. WIRING DIAGRAM 4.4.1. NR-A Model ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 4 4.6.20. Bypass Mixing Valve (“Non-A” Series) 5. TROUBLESHOOTING 5.1. ERROR CODE LIST 5.2. 01ERROR 5.3. 03ERROR 5.4. 04ERROR 5.5. 07ERROR 5.6. 08ERROR 5.7. 09ERROR 5.8. 10ERROR 5.9. 12ERROR 5.10. 15ERROR 5.11. 16ERROR ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 5 8. REPLACEMENT OF PARTS 8.1. REPLACEMENT PROCEDURE 8.2. COMPONENTS REPLACEMENT INSTRUCTIONS 8.2.1. PCB 8.2.2. Fuse 8.2.3. Transformer 8.2.4. Fan Motor(Combustion Air Blow) 8.2.5. Flame Rod 8.2.6. Ignition Transformer 8.2.7. APS ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 6 9.3. WATER WAY DISASSEMBLE (NR-A) 9.4. WATER WAY DISASSEMBLE (NR) 9.5. WATER WAY DISASSEMBLE (NP-A) 9.6. WATER WAY DISASSEMBLE (NP) 10. INSPECTION AND MAINTENANCE SCHEDULE 10.1. ANNUAL SERVICING 10.2. INSPECTION REPORT 10.3. MAINTENANCE REPORT ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 7: Revisions
Revisions Version Description of changes Date 1.00 First Issue 04/27/10 2.00 Format Revision July/20/10 ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 8: Navien Warranty
Navien America, Inc. (Navien) warrants this Navien Water Heater 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.The...
Page 9 The Applicable Period for this Labor Allowance for all water heater models is 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.
Page 10 Product Disposal Measures Dispose of components of the heating system that require replacement in an environmentally responsible manner. Make sure that condensate disposal method is in accordance with local regulations. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 11: Handling Of This Manual
Handling of This Manual Scope • This Service Manual is applicable to Navien Tankless Water Heater NR/NP Series. Product Model discrimination label located in 2 places. Precautions for Handling of This Manual • Navien America Inc. reserves all rights related to this manual •...
Page 12: Abbreviation And Definition
General name of NR-180A, NR-210A, and NR-240A NP-A General name of NP-180A, NP-210A and NP-240A General name of NR-180, NR-210, and NR-240 General name of NP-180, NP-210, and NP-240 “A” Series General name of NR-A, and NP-A “Non-A” Series General name of NR, and NP...
Page 13: 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 NR/NP series service Manual Version 2.0...
Page 14: Safety Precautions
And can be tightly closed, and out of flammable vapors. carried from other rooms children’s reach. to the main burner flame by air currents. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 15 Contact a licensed plumber or the local plumbing authority for further information. • This Navien Water Heater is factory se at 120 (NP Series: 140 ) for your safety and comfort. Increasing the set temperature increases the risk of accidental scalding.
Page 16 • 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 NR/NP series service Manual Version 2.0...
Page 17 • Installation condition may affect the servicing. Read all related information in the “Condensing Water Heater Manual”. • The Navien Water Heaters 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 18 Be sure the gas type and electricity voltage match the Rating Plate. • Use only the same gas type indicated on the rating plate of the Navien Water Heater. Using different gas type will cause abnormal combustion and water heater malfunction.
Page 19: Product Information
2. Product Information 2.1. Product Information Navien offers two series of tankless gas water heater; Navien Regular (NR) as residential models and Navien Premium (NP) as commercial models. Each series in-cludes the “A” model with an optional built-in Circulation Pump and a Mini Buffer Tank.
Page 20: Layout And Key Components
Gas Inlet Adapter BH2507396A Exhaust Duct BH2544004F Main Gas valve BH0901018A Exhaust Pipe BH2505401B GPS Venturi BH2507359B Air Intake Guide BH2543002C Gas Pipe BH2507509A Power Switch BH1426002A NASS9EXGPS01 Water Leakage Detector ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 21: Np-A Model
Gas Inlet Adapter BH2507396A Exhaust Pipe BH2505401B Main Gas valve BH0901018A Air Intake Guide BH2543002C GPS Venturi BH2507359B Power Switch BH1426002A Gas Pipe BH2507351A Water Leakage Detector NASS9EXGPS01 NCVM9EX00005 2-Way Valve BH0914002B ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 22: Nr Model
Exhaust Pipe BH2505401B Main Gas valve BH0901018A Air Intake Guide BH2543002C GPS Venturi BH2507359B Bypass Mixing Valve AAVC9EXMIX01 Gas Pipe BH2507351A Freeze Protect Switch BH1402001A NASS9EXGPS01 Mixing Trans BH1205013A NCVM9EX00005 ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 23: Np Model
Main Gas valve BH0901018A Air Intake Guide BH2543002C GPS Venturi BH2507359B NCVM9EX00005 Gas Pipe BH2507351A Freeze Protect Switch BH1402001A NASS9EXGPS01 Bypass Mixing Valve AAVC9EXMIX01 2-Way Valve BH0914002B Mixing Trans BH1205013A ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 24: Technical Data
(37 ~ 85 ) 3 Thermisters (In, Out 1, Out 2) Thermisters Q’ty 4 Thermisters (In, Out 1, Out 2, Mixing) Auto Firing System (Internal or External Recirculation) Freeze Protection Ceramic Heaters ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 25: Dimensions
3.2.1. NR-A, NP-A Model 1) Connection Diameter Description Diameter Exhaust 3” Air Intake 3” Hot Water Outlet 3/4” Recirculation Inlet 3/4” Cold Water Inlet 3/4” Gas Connection 3/4” 2) Dimensions Model ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 26: Nr, Np Model
3.2.2. NR, NP Model 1) Connection Diameter Description Diameter Exhaust 3” Air Intake 3” Hot Water Outlet 3/4” Cold Water Inlet 3/4” Gas Connection 3/4” 2) Dimensions Model ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 27: System Details
Primaty H/E Buffer tank Secondary H/E Flow sensor Check v/v Circulation pump Water adjustment v/v Main gas v/v 3-Way v/v Hot water Recirculation Cold water Fuel gas supply supply inlet ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 28: Np-A Model
Buffer tank Water adjustment v/v Secondary H/E Flow sensor Check v/v Circulation pump 2-Way v/v Main gas v/v 3-Way v/v Hot water Recirculation Cold water Fuel gas supply supply inlet ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 29: Nr Model
Fan motor Manifold Burner Primaty H/E Bypass Mixing v/v Secondary H/E Flow sensor Water adjustment v/v Main gas v/v Hot water Cold water Fuel gas supply supply inlet ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 30: Np Model
Fan motor Manifold Burner Primaty H/E Bypass Mixing v/v Water adjustment v/v Secondary H/E Flow sensor 2-Way v/v Main gas v/v Hot water Cold water Fuel gas supply supply inlet ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 31: Operation Flow Chart
Igniter OFF? Lock-out: GV/Igniter Power 004E Flow Sensor >= 0.53 GPM Lock-out: Igniter ON 015E Lock-out: Igniter ON 027E for 1 sec? Lock-out: 009E Igniter OFF Lock-out: 010E FM Control normal? ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 32 Flame OFF straight 20 times during Flame OFF? 012E burner operation? FM start-up: Lock-out: FM and AP normal? 009E Lock-out: Excess Air Pressure? 010E Lock-out: APS normal? 027E Lock-out: GPS normal? 035E GARC ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 33 SV1 ON SV1 ON SV2 OFF SV2 OFF SV2 ON SGV1 OFF? SGV2 OFF? Igniter OFF? SGV2 OFF? Igniter OFF? Igniter OFF? Lock-out: HC <= minimum? Faucet Close 015E Burner Operation ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 34 Mixing Valve Abnormal? 033E 045E >= 248 Lock-out: Lock-out: Outlet Thermistor 2 Cascade Connection 041E 043E >= 14 Abnormal? Lock-out: Outlet Thermistor 2 042E >= 248 Thermistor Connection Abnormal? Lock-out: 044E ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 35 Combustion fan runs for a short period of time at low speed. 5. Standby Mode • PCB monitors water temperature and remote controls. • Freeze protection is activated as needed. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 36: Dip Switch Settings
See ‘Model Selection’ below Model Selection Burner Operation Mode Model Selection Dip Switch No. Dip Switch No. Normal Operation NR/NP-180, NR/NP-180A Maximum Operation NR/NP-210, NR/NP-210A Minimum Operation NR/NP-180, NR/NP-180A 3-Stage Minimum ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 37 No Recirculation With Pump (NR-180A, NR-210A, NR-240A, External Recirculation NP-180A, NP-210A, NP-240A) Internal Recirculation Without Pump (NR-180, NR -210, NR -240, NP-180, NP -210, NP -240) Temperature Selection Temperatures With Pump Premium DIP Switch # (NR-180A, NR-210A, NR-240A, Models NP-180A, NP-210A, NP-240A) (NP,NP-A Series) ˚F (˚C)
Page 38: Wiring Diagram
4.4. Wiring Diagram 4.4.1. NR-A Model ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 42: Electrical Diagnostic Points
4.5. Electrical Diagnostic Points ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 43 Bypass Voltage changes according to the Mixing Valve WHITE-BLACK DC 0~13 V Mixing Valve operating. BLUE-YELLOW PULSE Check Pulse. PINK-ORANGE AC 17 V BLUE-BLUE AC 14~20 V Confirm output voltage. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 44 Power trans AC 97~138 V Confirm output voltage WHITE-BLACK AC120V Motorized ON : AC 97~138 V Confirm voltage as Motorized BLACK-BLUE-RED 2-way Valve OFF : 0 V 2-way Valve operating. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 45: Key Components Description
Error Code E015 1. Visual inspection: Connection and/or breakage of wires and Diagnostic or burn marks on the PCB Color / Number of wires ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 46: Thermal Fuse
2. The water heater is not operating. 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 NR/NP series service Manual Version 2.0...
Page 47: 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 NR/NP series service Manual Version 2.0...
Page 48: High Limit Switch Or Exhaust Limit Switch
2. Voltage check: Check range of voltage shown below. 1. Yellow – Yellow : DC 4 ~ 6 V Color / Number of wires 2. Red – Red : DC 4 ~ 6 V Flue Gas Water ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 49: Thermistor
3. Red – Red : DC 0 ~ 5 V Number of wires 4. Yellow – Yellow : DC 0 ~ 5 V 5. Resistance-Open=infinite; Shorted=0 Nomal =4.121 at 113 ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 50: Fan Motor
: 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 ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 51: Flame Rod Ass'y
2. No effects on the unit, however, the durability of the igniter wears down. Error Code E009, E010, E027 Diagnostic 1. Visual inspection: Connection and/or breakage of wires. Color / Number of wires Flame rod Bracket wire Insulator (Ceramic) Igniter Flame rod ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 52: Ignition Transformer
Blue – Blue : On : AC 97 ~ 138 V Color / Number of wires Off : 0 V Input Voltage Ouput Voltage Ouput Voltage 115V, 60Hz 19KV ± 2KV 10mA ± 2mA ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 53: Aps
2. Voltage check: Check range of voltage shown below. 1. Red- black : DC 5 V Color / Number of wires 2. White – black : DC 0.3 ~ 4.5 V ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 54: Manifold
: On : DC 83 ~ 120 V, Off : 0 V Model : 180 Nozzle Model : 210/240 Solenoid Valve Fuel Gas Supply 2 Stage 1 Stage 3 Stage ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 55: Main Gas Valve
2. Yellow - yellow : ON – DC83 ~ 120 V, OFF – 0 V 3. Red – red : ON – DC83 ~ 120 V, OFF – 0 V SV2 PV [Gas Flow Diragram] ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 56: Gps
2. Voltage check: Check range of voltage shown below. 1. Red- black : DC 5 V Color / Number of wires 2. White – black : DC 0.3 ~ 4.5 V ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 57: Burner
3. Ignition failure. Error Code E003, E004, E012 Visual inspection: Excessive dust deposit on the burner (fin) surface and Diagnostic /or unstable flame conditions during operation. Color / Number of wires ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 58: Water Adjustment Valve
Water Adjust (CW)(N) : Blue – yellow : ON AC 97~138 V, OFF 0 V Water Adjust (CCW)(N) : Blue –orange : ON AC 97~138 V, OFF 0 V Feedback Flow adjust ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 59: Flow Sensor
1. Red- black : DC 5 V Number of wires 2. White – black : DC 0.3 ~ 4.5 V Flow Rate Range 0.5 ~8.0 GPM Maximum Pressure 150 psi ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 60: Primary Heat Exchanger
Error Code 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 NR/NP series service Manual Version 2.0...
Page 61: Secondary Heat Exchanger
Error Code 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 NR/NP series service Manual Version 2.0...
Page 62: Buffer Tank ("A" Series)
1. Stop operating once detecting water leakage. Effects 2. Temperature fluctuations in the hot water outlet. E037 Error Code Diagnostic 1. Visual inspection : check the mini buffer tank appearance crack Color / Number of wires ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 63: Circulation Pump ("A" Series)
3. Abnormal of external circulation caused by preheating failure. E038 Error Code 1. Visual inspection: check the circulation pump connection wire. Diagnostic 2. Voltage check: Check range of voltage shown below. Color / Number of wires ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 64: Bypass Mixing Valve ("Non-A" Series)
Flow adjust The physical appearance of the bypass mixing valve is similar to that of the water adjustment valve. However, their functions differ and cannot be substituted for each other. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 65: Troubleshooting
2. Clean the inlet water strainer Manual E016 Overheating of heat exchanger (part #62). 3. Check the water adjustment valve(part #16) 4. Check the heat exchanger; flush with a cleaning solution ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 66 E035 Abnormal activity of the gas Automatic 2. Check hose connection pressure sensor 3. Replace GPS. Communication failure 1. Contact to Navien tech. dept. Automatic E036 1. Close cold water main. E037 Water Leak Inside unit Manual 2. Replace leaking parts.
Page 67: 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 thermistor, Check unit remove the connector from the PCB. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 68 DIP S/W set-ting error. DIP Switch Capacity Model Remark (Btu/h) Other trouble NR-180(A)/NP-180(A) 150,000 NR-210(A)/NP-210(A) 180,000 NR-240(A)/NP-240(A) 199,000 If the trouble continues despite the checking of above items, Defective replace the PCB. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 69: 03Error
Disassemble the manifold and check the nozzle. Check the flue and air supply (downward installation / rainwater collected) If the trouble continues despite the checking of above items, replace the PCB. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 70 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 NR/NP series service Manual Version 2.0...
Page 71 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 NR/NP series service Manual Version 2.0...
Page 72 An ignition fail may occur due to improper gap, while discharge gap and shape seems normal when checked via the flame monitoring window. Therefore, it is required to check the gap after disassembly. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 73 Replace the PCB if power is not supplied. Main Gas Valve If power supply is normal, check if the coil is open. Check if the solenoid valve works properly. Feel or hear a click. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 74 The system works but combustion is not normal due to the defective Air pressur sensor air pressure sensor. Flame blo-wout noise occurs at ignition < Defective air pressure hose > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 75 Disassemble the manifold and check the nozzle (Stage 1). in the nozzle. Defective air Defective air Check if rainwater is collected due to downward air supply pipe. supply supply ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 76 3. Remove 2 manifold fixing screws. 5. Use a screw driver to remove 4. Remove multi-stage valve. the valve. Stage 2 Stage 1 Stage 3 6. Disassemble the manifold. 7. Check the nozzles. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 77: 04Error
Is the flame detected Clean or replace flame rod during no burner openrarion? 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 NR/NP series service Manual Version 2.0...
Page 78 If gas leaks, close the main gas valve and repair the unit before usin the system. If the trouble continues despite the checking of above items, Other trouble Defective PCB replace the PCB. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 79: 07Error
Resistance between two red wires of CN 13 is from 0.8 to 20k ohm at normal condition. Caution: B efore measuring resistance of the Check connector thermistor, remove the connector from the PCB ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 80 If the trouble continues despite the checking of above items, Defective Other trouble replace the PCB. <Hot water temperature sensor / <Check if the hot water temperature Red line 2P> sensor line is open> ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 81: 08Error
Resistance between two red wires of CN 13 is from 0.8 to 20k ohm at normal condition. Caution: B efore measuring resistance of the Check connector thermistor, remove the connector from the PCB ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 82 If the trouble continues despite the checking of above items, Defective Other trouble replace the PCB. <Hot water temperature sensor / <Check if the hot water temperature Red line 2P> sensor line is open> ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 83: 09Error
Check items 4. If the blower connector is wet due to any reason including leakage, take the corrective action. 5. Check for loose connection of white tower on PCB ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 84 CN 8: 120 - 180VDC Replace fan assembly Is there any pulse output from the fan motor? Check the voltage between black and white wire of CN 8: 2 - 8VDC Replace PCB ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 85 3. If RPM is low or there is a sensor circuit error, replace the blower. 4. If the trouble continues despite the checking of above items, replace the PCB. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 86: 10Error
5. Check the flue and exhaust environment. (Inflow of exhaust gas generates noise.) 6. Check if the air supply/exhaust flue is clogged (rainwater collected due to dent or downward installation). 7. Defective air pressure sensor or PCB. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 87 CN 6: 0.3 - 4.0VDC Does the fan moter have Remove all the restrictions in airflow normal operation voltage? around unit anf check the vent pipe Replace tube Check vent and connector ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 88 Remove bottom of trap and verify it is not plugged 1. Replace the blower if the blower RPM is considerably low. Air pressure Defective blower error 2. Check the blower rpm displayed on the controller. (r.320 3200 rpm) ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 89 If the same trouble continues after reviewing of the above items, 1. replace the air pressure sensor in case the air pressure sensing Other error Defective PCB standard is abnormal, or 2. Replace the PCB. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 90: 12Error
Check the gas pressure sufficient gas pressure? Gas Pressure Natural Gas: 5″ - 10.5″ w.c LP Gas: 8.0 - 13.0 w.c Check the burner assembly, flame rod and gas valve assembly ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 91 Adjust differential pressure with the meter after ignition. ignition PCB DIP S/W 2,3 ON / Stage 3 MIN main gas valve. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 92 Low gas pressure causes blowout of flame. Thick flame causes noise and accidental fire. If the trouble continues despite the checking of above items, replace Other trouble Defective PCB the PCB. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 93: 15Error
Power supply grounding noise causes malfunction. Disconnect ground by applying a tape on the grounding Power supply grounding noise terminal in the receptacle, and check if the PCB works normally. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 94: 16Error
Check the resistance betweenteo white wires of CN 13: short-circuit(016E) Check the resistance betweenteo white wires of CN 13: short-circuit(030E) Caution: Measuning should be done at leat 30 minutes after error. Replace PCB ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 95 Check, with a tester, if the temperature fuse is disconnected. Defective fuse is discon- If the fuse is disconnected, replace the part and check the safety device nected. cause of overheating. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 96 The surface temperature rises due to defective main heat exchanger. exchanger Replace the main heat exchanger. overheated If the trouble continues despite the checking of above items, Defective the PCB is defective. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 97: 21Error
If the trouble continues despite the checking of above items, Defective Other trouble replace the PCB. <Heat exchanger input temperature sensor / <Check if the hot water temperature sensor is open> connector, Black 2P> Error type : MΩ Open ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 98: 22Error
Resistance between two red wires of CN 13 is from 0.8 to 20k ohm at normal condition. Caution: Before measuring resistance of the thermistor, Check connector remove the connector from the PCB. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 99 If the trouble continues despite the checking of above items, Defective Other trouble replace the PCB. < Heat exchanger input temperature sensor / < Check if the hot water tem-perature sensor is open > connector, Black 2P > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 100: 27Error
CN 6: 0.2 - 0.6VDC During fan motor operation, Replace APS is 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 NR/NP series service Manual Version 2.0...
Page 101 An error occurs if the air volume sensor voltage of 1.20V is detected before pre-purge. If the trouble continues despite the checking of above items, Defective Other trouble replace the PCB. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 102: 30Error
Check the resistance betweenteo white wires of CN 13: short-circuit(016E) Check the resistance betweenteo white wires of CN 13: short-circuit(030E) Caution: Measuning should be done at leat 30 minutes after error. Replace PCB ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 103 Remove the PCB and check, with a tester, the resistance (M Ω defect). < Check the overheat controller > If the trouble continues despite the checking of above items, Defective Other trouble replace the PCB. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 104: 32Error
If the trouble continues despite the checking of above items, Defective Other trouble replace the PCB. <Heat exchanger input temperature sensor / <Check if the hot water temperature sensor is open> connector, Black 2P> Error type : MΩ Open ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 105: 33Error
If the trouble continues despite the checking of above items, Defective Other trouble replace the PCB. < Direct water temperature sensor / Blue 2P > < Check the hot water temperature sensor > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 106: 34Error
2. Defective PCB. Replace Water Adjust Valve Water Adjust Valve Feed Back Or Replace PCB output voltage normal? Check the voltage between black and white wire of CN 22: 0.5 - 3.0V ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 107 3. Check the water adjustment valve output value (AD) displayed but error occurs sensor on the PCB. On the display, F.15 or lower means the valve is open, and F.240 or higher means the valve is closed ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 108 5. Pull out the water adjustment valve power connector. (Keep the water adjustment valve feedback sensor connected.) 6. Plug the power cord, and start the unit while using hot water. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 109: 35Error
CN 7: 0.2 - 0.6VDC 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 NR/NP series service Manual Version 2.0...
Page 110 Gas pressure hose hose is pulled is pulled out any damage on the hose. If the trouble continues despite the checking of above items, Defective Other trouble replace the PCB. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 111: 36Error
OFF for the remaining systems. < Communication switch (DIP S/W No. 6)> If the trouble continues despite the checking of above items, Defective Other trouble the PCB is defective. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 112: 37Error
3. Check if the PCB works normally. Is there any water leakage Is there any water leakage Replace water leakage detector detector normally inside water heater? operating? Replace leaking part Check connector ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 113 PCB is defective. Defective Other trouble Check to make sure that the ends of the wires are both not contacting the cabinet. < Water leak sensor wire : Blue 2P> ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 114: 38Error
Circulation PUMP normal PUMP output voltage Replace circulation PUMP operating? normal? Check the voltage of CN13: Over 97V AC Replace PCB Check water flow sensor Or check connector ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 115 Defective pump < Circulation pump wire: Blue 2P > < Circulation pump > If the trouble continues despite the checking of above items, Defective Other trouble the PCB is defective. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 116 1. Check the supply of cold water. (Frozen / locked valve) 2. Defective flow sensor. Check items 3. Defective PCB. Cancelation cascade system and faucet open Check supply cold water Water flow out? Check connector Or Replace water flow sensor ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 117 If the flow displayed on the PCB is 00.0, and the impeller rotates when you blow it, the hall sensor of the flow sensor is defective. The hall sensor is substituted by the CH flow sensor. >> Please clarify this procedure ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 118 6. The impeller housing is disassembled as shown in the figure This is compatible with the NCN flow sensor. if you pull out the top/bottom caps. Clean the impeller axis. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 119: 44Error
1. Check the position of each temperature sensor. 2. Defective temperature sensor. Check items 3. Defective PCB. Thermistors connection Thermistors connection change normal? Check thermistors ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 120 Replace the temperature sensor if the value is out of the standard sensor resistance value. If the trouble continues despite the checking of above items, Defective Other trouble the PCB is defective. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 121: 45Error
1. Check the connector is connected between bypass mixing valve and PCB. 2. Defective Mixing trans. Check items 3. Defective Bypass Mixing valve 4. Defective PCB. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 122 Check the voltage and pulse of CN24 BLACK-RED : DC 7~13 V BLACK-WHITE : DC 0~13 V PINK-ORANGE : -12 ~ 12 VDC (pulse) BLUE-YELLOW : -12 ~ 12 VDC (pulse) Replace PCB ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 123 Check the voltage between blue and blue wire of CN23 : (14 ~20VAC) Trans If the trouble continues despite the checking of above items, Defective Other trouble replace the PCB. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 124: 48Error
2. Check if the gas pressure sensor hose is damaged. 3. Check if the gas pressure sensor is defective. 4. Check if the PCB works normally. LPG Gas enough? Fill the LPG Gas Check GPS Or supply Iine ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 125 Operating voltage (Black+Red) : DC 5 V Sensor output voltage (Black+White) : DC 0.3~4.0 V If the trouble continues despite the checking of above items, Defective Other trouble replace the PCB. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 126: Troubleshooting Guide By Symptom
2. The heat exchanger is clogged due to foreign substance. Clean the main heat exchanger by removing scale. Replace the main heat exchanger if the error continues after the cleaning. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 127 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 NR/NP series service Manual Version 2.0...
Page 128: Hot Water
For the A model, the system performs the internal/ external circulation preheating when 24-hour timer is set on the Pre-heating Cold water flows temporally does not work remote controller. Therefore, make sure to check the time setting ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 129: Circuit Breaker Operates
Remote controller Check the wire of the PCB, and take the action separately for wiring error and power defective PCB, respectively. If the power supply is normal, replace the remote controller. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 130: 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 NR/NP series service Manual Version 2.0...
Page 131: Measuring Gas Pressure Setting
7. When the Navien water heater is at maximum burn, check the inlet gas pressure reading on the manometer; it should read between 5”(6” 180 model) ~10.5” W.C for Natural gas between 8.0”...
Page 132: 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 water heater 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 133 2.20″ ± 0.08″ W.C NR/NP-240(A) Propane Gas 1.30″ ± 0.08″ W.C 3.86″ ± 0.08″ W.C gas valve Proportional valve Air Pressure Minimum Modulating Gas Pressure PCB Board Manometer Maximum Modulating gas valve ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 134: Maintenance
3. Twist and remove the cap. 4. clean out the siphon. 5. Replace the cap and the retaining clip. 6. pour the water into the exhaust connection to fill the siphon. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 135: Cleaning The Intake Air Filter
7. Once the filter is back on the intake pipe, reset the fan back to its original position. 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 NR/NP series service Manual Version 2.0...
Page 136: Flushing The Heat Exchanger
12. Remove the inline filter at the cold water inlet and clean out any residue. 13. Place the filter back into the unit. 14. Restore electrical power to the water heater. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 137: 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 138: Components Replacement Instructions
6. Loosen the PCB 2 screw from bottom 12. Turn on water supply, power supply, base. and gas supply. 13. Perform the measuring NOTE Connecting ports must be right color and place. < Figure 2 > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 139: Fuse
5. Rotate the PCB to the left side. 6. Remove the capsule (A)’s B/C connected to the power cable. < Figure 5 > < Figure 2 > < Figure 6 > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 140: Transformer
9. Tighten the 2 screws from 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 NR/NP series service Manual Version 2.0...
Page 141: Fan Motor(Combustion Air Blow)
It will be damaged to fan housing. 2. Confirm whether the screws tighten enough or not. 3. Confirm whether there are unnecessar noises after reinstalled fan. < Figure 9 > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 142: Flame Rod
13. Install front panel using 4(four) screws. 14. Turn on water supply, power supply, and gas supply. NOTE Always use factory seal packing between the electrode and burner assembly. < Figure 12> ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 143: Ignition Transformer
PCB. NOTE 1. Check up whether fixing exactly done. 2. Check up the connecting terminal. < Figure 14 > 8. Loosen the two igniter screws. < Figure 15> ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 144: Aps
13. Install front panel using 4(four) screws. 14. Turn on water supply, power supply, and gas supply. NOTE As re-assemble the air pressure sensor, careful with right size and direction. < Figure 17> ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 145: Manifold
11. Reinstall gas valve wires into the manifold < Figure 20> to be replaced. 12. Attach the manifold and secured with 7. Pull out the gas pipe. screws. 8. Loosen the 2 manifold fixing screws. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 146 18. Check for gas leaks. NOTE 1. Always replace with new gasket. 2. Wiring should be in right position. 3. Always use right part(Oring) and right size and place to pipe. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 147: Main Gas Valve
< Figure 23> where the assembly attaches to the gas 8. Detach the gas pressure sensor tube. connection. Make sure the old O-ring removed and discarded. < Figure 24 > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 148 19. Check for gas leaks. NOTE 1. Always replace with new gasket. 2. Wiring should be in right position. 3. Always use right part(O-ring) and right size and place to pipe ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 149: Gps
14. Turn on water supply, power supply, and 7. Loosen the gas pressure sensor lower-side gas supply. 2 screws from base. NOTE Always use right type of tube and right place. < Figure 27 > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 150: 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 to trap. < Figure 30 > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 151: Water Adjustment Valve
< Figure 32 > 7. Remove the water adjustment outlet pipe from the water adjustment valve. 8. Remove the water adjustment valve from the cold water inlet adapter. < Figure 33 > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 152: Flow Sensor
13. Turn on water supply, power supply, and gas supply. 14. Open a hot water tap and ensure there are no leaks at the water heater. < Figure 35 > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 153: Buffer Tank ("A" Series)
7. Loosen the 4 buffer tank screws. 2. Use right size of Oring. 3. When draining, use caution not to wet electrical components. < Figure 38 > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 154: Circulation Pump ("A"Series)
7. Open the drain plug on the pump. 8. Loosen the screw from the 3-way valve. Loosen the 3 screw from bottom base. 9. Remove the stainless clip. < Figure 42 > < Figure 40 > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 155 2. Place red gasket ring on top of the circulation pump and screw on the brass (stainless) nut; be sure not to cross thread; over tightening may damage gasket. ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 156: 3-Way Valve ("A" Series)
17. Turn on water supply, power supply, and gas supply. 18. Open a hot water tap and ensure there are no leaks at the water heater. < Figure 44 > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 157: 2-Way Valve ("Np-A" "Np" Series)
17. Turn on water supply, power supply, and 2-way valve. gas supply. 18. Open a hot water tap and ensure there are no leaks at the water heater. < Figure 47 > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 158: Bypass Mixing Valve ("Non-A" Series)
17. Turn on water supply, power supply, and gas supply. 18. Open a hot water tap and ensure there are no leaks at the water heater. < Figure 50 > ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 159: Components Diagram And Part List
9. Components Diagram and Part List 9.1. Case Disassemble (NR/NP – A, NR/NP) ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 160 “Non-A” Series Screw (D4 x 8) BH1705007A Bolt (M4 x 16) BH1603009A Screw (D4 x 16) BH1708004A Freeze protect switch BH1402001A Only “Non-A” Freeze protect S/W bracket BH2505423A Only “Non-A” ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 161: Burner Disassemble (Nr/Np - A, Nr/Np)
9.2. Burner Disassemble (NR/NP – A, NR/NP) ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 162 Air pressure sensor NASS9EX00009 Burner bracket R BH2501443C Burner bracket L BH2501444C Fan motor damper BH2505403C APS venturi BH2501413A APS venturi packing BH2405031A BH1419012A Thermal fuse BH1419013A 210/240 Ignition transformer BH1201041D ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 163 Screw (D4 x 25L) BH1701030A Screw (D4 x 12L) BH1708003A Screw (D4 x 14L, STS) BH1701031A Bolt (M4 x 10L, STS) BH1611006A Bolt (M4 x 10L) BH1611005A Bolt (M4 x 6L) BH1611001A ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 164: Water Way Disassemble (Nr-A)
9.3. Water Way Disassemble (NR-A) ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 165: Water Way Disassemble (Nr)
9.4. Water Way Disassemble (NR) ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 166: Water Way Disassemble (Np-A)
9.5. Water Way Disassemble (NP-A) ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 167: Water Way Disassemble (Np)
9.5. Water Way Disassemble (NP) ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 168 Exhaust limit switch BH1401027A Circulation pump NAPU9GLPCT30 “A” Series BH2507527B NR-A BH2507529C NP-A Secondary H/E inlet pipe BH2507573B BH2507612B Pump drain coke BH2505314B “A” Series Cold water inlet adapter AAVC9EX00016B ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 169 H-type clip BH2501541A NR, NP-A Syphon hose clip BH2507310A O-ring BH2422025A BH2507577B NR-180 BH2507578B NR-210/240 Bypass pipe BH2507615B NP-180 BH2507616B NP-210/240 Bolt M4 x 8L BH1603015A Check valve BH0913004D “A” Series ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 170 T-type adapter (clip) BH2507474D Freeze protect switch BH1402001A “Non-A” Series Freeze protect S/W bracket BH2505423A “Non-A” Series BH2507536C NR-A 3-Way valve inlet pipe BH2507537C NP-A Motorized 2-way valve AAVC9EX00014A NP, NP-A ©Navien America Inc. 2010 NR/NP series service Manual Version 2.0...
Page 171: Inspection And Maintenance Schedule
- Draining the water heater 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 NR/NP series service Manual Version 2.0...
Page 172: 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 NR/NP series service Manual Version 2.0...
Page 173: Maintenance Report
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 NR/NP series service Manual Version 2.0...

This manual is also suitable for:

Np-180a Np-210 Nr-180 Nr-180a Nr-210a Np-210a ... Show all

Navien NP-180 Service Manual

1 Safety Considerations

2 Product Information

3 Technical Data

4 System Details

5 Troubleshooting

6 Inspection

7 Maintenance

8 Replacement of Parts

9 Components Diagram and Part List

10 Inspection and Maintenance Schedule

Quick Links

Troubleshooting

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Summary of Contents for Navien NP-180

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Table of Contents