Navien CH-180 User manual

CH-180 CH-210 CH-240
CH-240 ASME
Combination Water Heater
/ Heating Boiler
MODEL
CH
Combination Water Heater / Heating Boiler
Combination Water Heater / Heating Boiler
Ver. 1.00
Service Manual
Service Manual
Service Manual
Navien America, Inc.
20 Goodyear lrvine, CA 92618
TEL [phone] FAX [phone]
www.naviennamerica.com
1st Edition - July 2010
No. 20A-GT-002
 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
 Installation and service must be performed by a qualified installer,
service agency or the gas supplier.
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 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.

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Contents
REVISIONS 5
NAVIEN WARRANTY 6
HANDLING OF THIS MANUAL 8
ABBREVIATION AND DEFINITION 9
1. SAFETY CONSIDERATIONS 10
1.1. SAFETY DEFINITIONS 10
1.2. LIST OF SAFETY SYMBOLS IN THIS MANUAL 10
1.3. SYMBOLS USED IN THE INSTRUCTIONS 10
1.4. SAFETY PRECAUTIONS 11
2. PRODUCT INFORMATION 16
2.1. PRODUCT INFORMATION 16
2.2. LAYOUT AND KEY COMPONENTS 17
3. TECHNICAL DATA 18
3.1. GENERAL SPECIFICATIONS 18
3.2. DIMENSIONS 19
4. SYSTEM DETAILS 20
4.1. SCHEMATIC AND WATER FLOW DIAGRAM 20
4.1.1. Space Heating Mode 20
4.1.2. Domestic Hot Water Mode 21
4.2. OPERATION FLOW CHART 22
4.3. DIP SWITCH SETTINGS 26
4.4. WIRING DIAGRAM 29
4.5. ELECTRICAL DIAGNOSTIC POINTS 30
4.6. KEY COMPONENTS DESCRIPTION 33
4.6.1. PCB 33
4.6.2. Thermal Fuse 34
4.6.3. Transformer 35
4.6.4. High Limit Switch or Exhaust Limit Switch 36
4.6.5. Thermistor 37
4.6.6. Fan motor 38

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4.6.7. Flame Rod Ass’y 39
4.6.8. Ignition Transformer 40
4.6.9. APS 41
4.6.10. Manifold 42
4.6.11. Main Gas Valve 43
4.6.12. GPS 44
4.6.13. Burner 45
4.6.14. Flow Sensor 46
4.6.15. Primary Heat Exchanger 47
4.6.16. Secondary Heat Exchanger 48
4.6.17. DHW Heat Exchanger 49
4.6.18. Circulation Pump 50
4.6.19. 3-Way Valve 51
4.6.20. Water pressure Sensor 52
4.6.21. Auto Feeder Valve 53
5 . TROUBLESHOOTING 54
5.1. ERROR CODE LIST 54
5.2. 01ERROR 56
5.3. 02ERROR 59
5.4. 03ERROR 61
5.5. 04ERROR 69
5.6. 05ERROR 71
5.7. 06ERROR 72
5.8. 07ERROR 73
5.9. 08ERROR 74
5.10. 09ERROR 75
5.11. 10ERROR 78
5.12. 11ERROR 81
5.13. 12ERROR 82
5.13. 13ERROR 84
5.15. 15ERROR 86
5.16. 16ERROR 87
5.17. 18ERROR 90
5.18. 19ERROR 92
5.19. 21ERROR 94
5.20. 22ERROR 96
5.21. 27ERROR 98

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5.22. 28ERROR 100
5.23. 30ERROR 102
5.24. 35ERROR 103
5.25. 36ERROR 105
5.26. 39ERROR 106
5.27. 40ERROR 107
5.28. TROUBLESHOOTING GUIDE BY SYMPTOM 108
5.28.1. Noise 108
5.28.2. Hot water 109
5.28.3. Space Heating 110
6. INSPECTION 112
6.1. PREPARING THE BOILER FOR INSPECTION 112
6.2. MEASURING GAS PRESSURE SETTING 113
6.2.1. How to Check Inlet Gas Pressure 113
6.2.2. Adjusting the Gas-Air Ratio 114
7. MAINTENANCE 116
7.1. DRAINING THE BOILER 116
7.2. CLEANING THE INTAKE AIR FILTER 117
7.3. FLUSHING THE HEAT EXCHANGER 117
8. REPLACEMENT OF PARTS 118
8.1. REPLACEMENT PROCEDURE 118
8.2. COMPONENTS REPLACEMENT INSTRUCTIONS 119
8.2.1. PCB 119
8.2.2. Fuse 120
8.2.3. Transformer 121
8.2.4. Fan Motor(Combustion Air ) 122
8.2.5. Flame Rod 123
8.2.6. Ignition Transformer 124
8.2.7. APS 125
8.2.8. Manifold 126
8.2.9. Main Gas Valve 127
8.2.10. GPS 129
8.2.11. Condensation Trap 130
8.2.12. Flow Sensor 131
8.2.13. Circulation Pump 132
8.2.14. 3-way Valve 133
8.2.15. Water Pressure Sensor 134

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8.2.16. Space Heating Strainer (Filter Cleaning or Strainer Replace) 135
8.2.17. Auto Feeder Valve 136
8.2.18. Domestic Hot Water Exchanger 137
8.2.19. Domestic Hot Water Outlet Collar 138
9. COMPONENTS DIAGRAM AND PART LIST 139
9.1. CASE DISASSEMBLE 139
9.2. BURNER DISASSEMBLE 141
9.3. WATER WAY DISASSEMBLE 144
10. INSPECTION AND MAINTENANCE SCHEDULE 147
10.1. ANNUAL SERVICING 147
10.2. INSPECTION REPORT 148
10.3. MAINTENANCE REPORT 151

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Revisions
Version Description of changes Date
1.00 First Issue July/30/10

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Navien Warranty
GENERAL
APPLICABLE WARRANTY PERIODS
Period of Coverage
Heat Exchanger
10 years 5 years
All other Parts and Components
Navien America, Inc. (Navien) warrants this Navien gas condensing combination water
heater / 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. The
replacement component part(s) must be Navien Original factory component part(s). The
replacement component part(s) will be warranted only for the remaining portion of the
original component part’s Applicable Warranty Period.
EFFECTIVE DATE
The Effective Date of warranty coverage (the beginning of the Applicable Warranty Periods)
is the date of purchase of this combination water heater / boiler, if properly registered.
HEAT EXCHANGER WARRANTY
The Applicable Warranty Period for a CH series Heat Exchanger failure installed in a
Residential application is Ten (10) years from the Effective Date.
PARTS WARRANTY (excluding heat exchanger)
The Applicable Warranty Period for a CH series Part(s) failure installed in a Residential
application is Five (5) years from the Effective Date.
Proof of purchase is required to obtain warranty service. You can show proof
of purchase with dated sales receipt, by completing and mailing the enclosed
warranty registration card within 30 days of purchasing the product or by registering
online at www.navienamerica.com

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LABOR ALLOWANCE:
The Applicable Period for this Labor Allowance for all Combination Water heater / boiler
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.
TRANSFERABILITY
WARRANTY EXCLUSIONS
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. The
warranty will be void if the combination water heater / boiler is relocated to any other location.
This warranty does not cover the following conditions:
Damages, malfunctions or failures resulting from failure to install the combination water heater / boiler
in accordance with applicable building codes, ordinances or normal plumbing and electrical trade
practices.
Damages, malfunctions or failures resulting from improper installation or failure to operate and
maintain the combination water heater / boiler in accordance with the manufacturer’s instructions
provided.
Performance problems caused by improper sizing of the combination water heater / boiler or the gas
supply line, the venting connection, combustion air openings, electric service voltage, wiring or
fusing.
Damages, malfunctions or the all failures caused by conversion from natural gas to LP gas or LP gas
to natural gas or attempt to operate with a type of gas not specified for the combination water heater
/ boiler.
Damages, malfunctions or failures caused by operating the combination water heater / boiler with
any parts removed or with parts that have been modified, altered or unapproved for installation.
Damages, malfunctions or failures caused by abuse, negligence, alteration, accident, fire, flood,
freezing, lightning and other acts of God.
Heat Exchanger failures caused by operating the combination water heater / boiler in a corrosive or
contaminated atmosphere.
Damages, malfunctions or failure caused by poor water quality, lime or mineral build-up or sediment
build-up.
Damages, malfunctions or failures caused by operating the unit at water temperatures outside the
factory calibrated temperature limits and/or exceeding the maximum setting of the high limit control.
Heat Exchanger failures caused by operating the combination water heater / boiler when it is not
supplied with potable water at all times.
Damages, malfunctions or failures caused by subjecting the heat exchanger to pressures or firing
rates greater or lesser than those shown on the rating plate.
Units installed outside of the fifty states (and the District of Columbia) of the United States of America
and outside of Canada.
Rating plate has been removed by an unauthorized person. A combination water heater / boiler
should not be operated if the rating plate has been removed.
Damage due to freezing.

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Handling of this manual
Scope
This Service Manual is applicable to Navien Boiler CH 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
• 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 “
Ù ” mark is used to indicate the chapter or section you should refer to its format
is as indicated below.
Ù {3.1 General Specification} of Ù {3.1}

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Abbreviation and definition
Abbreviation Description of changes
CH
NG
LP
AP
APS
DHW
FM
GARC
GPM
GPS
GV
MGV
MV
SGV
RPM
PCB
EMI
HTL
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
Gas Air Ratio Control
Gallon per Minute
Gas Pressure Sensor
Gas Valve : Main and Solenoid
Main Gas Valve
Modulating Valve
Solenoid Gas Valve
Round per Minute
Printed Circuit Board
Electromagnetic Interface
High Temperature Limiter

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1. Safety Considerations
1.1. Safety Definitions
1.2. List of safety symbols in this manual
1.3. Symbols Used in the Instructions
DANGER
WARNING
CAUTION
CAUTION
All Safety messages will refer to potential hazards. Precisely follow the instructions to
avoid the risk of injury.
The following symbols are used throughout the instructions to bring attention to
important information concerning the appliance.
This is the safety alert symbol. It is used to alert you of potential
personal injury hazards. Observe all of the safety messages that
follow this symbol to avoid possible injury of death.
Indicates an imminently hazardous situation which, if not avoided,
could result in severe injury or death.
Indicates a potential hazardous situation which, if not avoided,
could result in injury or death.
Indicates an imminent hazardous situation which , if not avoided,
may result in minor or moderate injury.
Used without the safety alert symbol indicates a potential hazardous
situation which, if not avoided, could result in property damage.
IMPORTANT
NOTE
Warns of a risk of material loss and environmental pollution.
Indicates additional information that is important but not related to
personal injury or property damage.

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1.4. Safety Precautions
DANGER
FLAMMABLE MATERIALS
Keep the area around the boiler clear and free from flammable materials.
• DO NOT place flammable liquids such as oils or gasoline, etc. near the
boiler.
• DO NOT place combustibles such as newspapers and laundry etc. near the
boiler or the venting system.
• DO NOT place or use hair spray, spray paint or any other type of spray can
near the boiler or the venting system (including the vent terminator).
• DO NOT place anything in or around the vent terminals that could obstruct
the air flow in and out of the boiler such as a clothes line.
DANGER
FLAMMABLE VAPORS
Vapors from flammable liquids will
explode and catch fire causing death
or severe burns.
Do not use or store flammable products
such as gasoline, solvents or adhesives
in the same room or area near the boiler
Keep flammable products:
far away from heater in approved
containers, tightly closed, andout of
children’s reach.
Boiler has a main burner flame:
which can come on at any time, and
may ignite flammable vapors.
Vapors:
cannot be seen, are heavier than air,
go a long way on the floor. And can
be carried from other rooms to the
main burner flame by air currents.
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DANGER
COMPROMISED VENTING SYSTEM
DANGER
Failure to follow the Venting Section of the installation manual may result in the
un-safe operation of this boiler. To avoid the risk of fire, explosion of asphyxiation
from carbon monoxide, never operate the boiler unless it is properly vented to
outside and has an adequate air supply for proper operation.
Be sure to inspect the vent terminator and the air intake pipe annually to ensure
safe operation of the boiler.
Immediately turn off and do not use the boiler if any of the vent pipes, vent
elbows and/or the boiler.
i.damaged in any way;
ii.have separated at a joint,
iii.are cracked or show evidence of corrosion, rusting or melting.
HOT WATER TEMPERATURE SETTING
To prevent scalding, check water temperature after servicing.
If the proposed boiler outlet temperature is above 125ȕ, 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.
Water temperature over 125ȕcan cause severe
burns instantly or death from scalds.
Households with small children, disabled, or elderly
persons may require 120ȕ(49Ȕ) or lower temperature
setting to prevent contact with “HOT” water.
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DANGER
WHAT TO DO IF YOU SMELL GAS
If you do not follow these instructions exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
DO NOT OPERATE THE BOILER.
DO NOT OPERATE ANY FAUCETS.
Smell all around the appliance area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will settle on the floor.
• Do not smoke.
• Extinguish any open flames and sparks.
• Do not operate light switches or electrical equipment switches.
• Do not use any phone in your building.
• Open the windows and doors.
• Close the gas shutoff valve.
• Keep people away from the danger zone.
• Observe the safety regulations of your local gas supplier, found on the gas
meter.
• 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.
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DANGER
IMPORTANT SAFETY PREAUTIONS
• Read and understand this safety information before operating or servicing this
Navien Boiler
• This manual must remain with the Navien Boiler.
• Confirm the location of the gas shut-off valve. Close the manual shut-off valve
if the Navien Boiler over becomes subjected to overheating, fire, flood, physical
damage or any other such damaging condition during servicing.
• DO NOT turn on the boiler unless water and gas supplies are fully opened.
• DO NOT turn on the boiler if cold water supply shut-off valve is closed.
• Make certain power to boiler is “OFF” before removing the front cover for any
reason.
• Label all wires prior to disconnection when servicing controls. Wiring errors can
cause improper and dangerous operation. Verify proper operation after servic
ing.
• Improper adjustment, alteration, service or maintenance can cause property
damage, personal injury, or death.
• To prevent scalding, always check the temperature of the hot water after servic
ing.
• DO NOT attempt to change the water temperature while someone is using the
boiler.
• DO NOT use parts other than those specified for this equipment.
• DO NOT operate the boiler if you feel something is wrong with the unit.
• DO NOT allow children to operate or otherwise handle the unit.
DANGER
INSTALLATION REQUIRMENT
• 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)” in the USA or the “National Gas and
Propane Installation Code (CAN/CSA B 149.1)” in Canada.
• Massachusetts code requires this boiler to be installed in accordance with
Massachusetts Plumbing and Fuel Gas Code 248 CMR Section 2.00 and 5.00.
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WARNING
GAS TYPE and AC VOLTAGE
If the unit does not match requirements, do not service, please con-
tact Navien immediately.
Navien America Inc. is not liable for any property damage and/of
personal injury resulting from unauthorized conversions.
• Use only the same gas type indicated on the
rating plate of the Navien Boiler.
Using different gas type will cause abnormal
combustion and boiler malfunction.
• Be sure to use 120 VAD, 60 Hz, minimum 2
A current. Using abnormally high or low AC
voltage may cause abnormal operation, and
may reduce the life expec tancy of this prod
uct.
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. sure the gas type and electricity voltage match the Rating Plate.
WARNING
GAS CONVERSION
Conversion of this unit from natural gas to propane or vice versa cannot be done
in the field. Please reconfirm gas type on the rating plate (left side of unit) before
servicing. DO NOT attempt any field conversion, this will result in dangerous
operating conditions and will void all warranty.
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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. The following four models are available according to their maximum
outputs.
The appliance always dives priority to DHW supply.
The appliance is designed to be used with a circulation pump, a divert valve
assembly, a flow sensor, a DHW plate heat exchanger and safety valve.
A separate heating expansion vessel is required.
Internal frost protection and an electronic control unit are incorporated within the
boiler. Any non-power stealing room thermostat or set of contacts can be used
with boiler.
Model
CH-180
CH-210
CH-240
CH-240 ASME
Maximum Heating Input
150,000 Btu/h
175,000 Btu/h
199,000 Btu/h
199,000 Btu/h
Maximum DHW Input(45ıRise)
6.5 Gal/m
7.7 Gal/m
8.6 Gal/m
8.6 Gal/m

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2.2. Layout and Key Components
No
1
2
3
4
5
6
7
8
9
10
11
12
13
No
14
15
16
17
18
19
20
21
22
23
24
25
26
Description
Intake Air Duct
Fan Motor
WPS
DHW Heat Exchanger
S/H Strainer
Motorized 3-Way Valve
Circulation Pump
S/H Supply Adaptor
S/H Return Adaptor
PCB Board
DHW Cold Water
Inlet Adaptor
Auto Feeder Valve
Main Gas Valve
Description
DHW Flow Sensor
Syphon
Transformer
Gas Pressure Sensor
Gas Pipe
Secondary Heat Exchanger
Primary Heat Exchanger
APS Venturi
Burner
Ignition Transformer
Air Pressure Sensor
Exhaust Duct
Exhaust Pipe
Navien Part No.
AASS9EXFS002
BH2501442C
BH1205011A
NASS9EXGPS01
BH2546021A
-
-
BH2501413A
PABNCW48KDBN_002
BH1201045A
NASS9EX00009
BH2544007D
BH2505401B
Navien Part No.
BH2505400B
NAFA9GSFB002
BH2507535A
PAS30KHE_005
BH1301020C
AAVC9EX00009
NAPU9GLPCT10
BH2507551A
BH2507551A
NACR1GS32301
BH2507396A
BH0904011A
BH0901018A

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3. Technical Data
3.1. General Specifications
Item CH-180 CH-210 CH-240,
CH-240 ASME
Heat Capacity
(Input)
Heat Capacity
(Input)
Dimensions
Weight
Installation Type
Venting Type
Ignition
Domestic Water Pressure
(min-max)
Heating Water Pressure
(min-max)
Efficiency AFUE
Gas Supply
Pressure
Manifold Gas
Pressure
Min.
Max.
Minimum Flow Rate
Connection Sizes
Heating
Supply/Return
1” NPT 3/4” NPT 1/2” NPT 3/4” NPT
98 ~ 140ı(37 ~ 60ç)
98 ~ 185ı(37 ~ 85ç)
Temperature
Range (R/C)
Safety Devices
Flame Rod, Overheat Cut-off Device, Ignition Operation Detector,
Water Temperature High Limit Switch,
Exhaust Temperature High Limit Switch
Plumb Easy Valve Set, Outdoor Sensor, Pressure Relief Valve,
Condensate Neutralizer, Communication Cable
Accessories
DHW
Space
Heating
DHW
Inlet/Outlet Auto feeder Gas Supply
0.5 GPM
NG: 0.4” W.C
NG: 3.7” W.C
NG: 0.4” W.C
NG: 3.0” W.C
NG: 0.6” W.C
NG: 4.0” W.C
Min. ~ Max.
Natural Gas
35°F Rise
45°F Rise
77°F Rise
8.3 Gal/m
6.5 Gal/m
3.8 Gal/m
10.0 Gal/m
7.7 Gal/m
4.6 Gal/m
W17” x H27”x D12”
74 lbs 84 lbs
Indoor / Outdoor Wall-Hung
Forced Draft Direct Vent
Electronic Ignition
15 ~ 150 Psi
7.0 ~ 30 Psi
91%
6.0”~10.5” W.C
11 Gal/m
8.6 Gal/m
5.1 Gal/m
Min: 17,000 Btu/h
Max: 150,000 Btu/h
Min: 20,000 Btu/h
Max: 175,000 Btu/h
Min: 20,000 Btu/h
Max: 199,000 Btu/h