Navien NP-180 User manual

Service
Manual
Service Manual
NR/NP Tankless Gas Water Heater
Tankless Gas Water Heater
Ver. 2.00
Navien America, Inc.
20 Goodyear lrvine, CA 92618
TEL [phone] FAX [phone]
www.naviennamerica.com
MODEL
2nd Edition - July 2010
No. 20A-GT-001
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 these instructions is not followed exactly, a fire or explosion may result
causing property damage, personal injury or death.
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.
NR-180 NP-180 NR-180A NP-180A
NR-210 NP-210 NR-210A NP-210A
NR-240 NP-240 NR-240A NP-240A
Tankless Gas Water Heater
NR/NP Series
Service
Manual
Service Manual
Service Manual

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Contents
REVISIONS 5
NAVIEN WARRANTY 6
HANDLING OF THIS MANUAL 9
ABBREVIATION AND DEFINITION 10
1. SAFETY CONSIDERATIONS 11
1.1. SAFETY DEFINITIONS 11
1.2. LIST OF SAFETY SYMBOLS IN THIS MANUAL 11
1.3. SYMBOLS USED THE INSTRUCTIONS 11
1.4. SAFETY PRECAUTIONS 12
2. PRODUCT INFORMATION 17
2.1. PRODUCT INFORMATION 17
2.2. LAYOUT AND KEY COMPONENTS 18
2.2.1. NR-A Model 18
2.2.2. NP-A Model 19
2.2.3. NR Model 20
2.2.4. NP Model 21
3. TECHNICAL DATA 22
3.1. GENERAL SPECIFICATIONS 22
3.2. DIMENSIONS 23
3.2.1. NR-A, NP-A Model 23
3.2.2. NR, NP Model 24
4. SYSTEM DETAILS 25
4.1. SCHEMATIC AND FLOW DIAGRAM 25
4.1.1. NR-A Model 25
4.1.2. NP-A Model 26
4.1.3. NR Model 27
4.1.4. NP Model 28
4.2. OPERATION FLOW CHART 29
4.3. DIP SWITCH SETTINGS 34
4.4. WIRING DIAGRAM 36
4.4.1. NR-A Model 36

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4.4.2. NP-A Model 37
4.4.3. NR Model 38
4.4.4. NP Model 39
4.5. ELECTRICAL DIAGNOSTIC POINTS 40
4.6. KEY COMPONENTS DESCRIPTION 43
4.6.1. PCB 43
4.6.2. Thermal Fuse 44
4.6.3. Transformer 45
4.6.4. High Limit Switch or Exhaust Limit Switch 46
4.6.5. Thermistor 47
4.6.6. Fan motor 48
4.6.7. Flame Rod Ass’y 49
4.6.8. Ignition Transformer 50
4.6.9. APS 51
4.6.10. Manifold 52
4.6.11. Main Gas Valve 53
4.6.12. GPS 54
4.6.13. Burner 55
4.6.14. Water Adjustment Valve 56
4.6.15. Flow Sensor 57
4.6.16. Primary Heat Exchanger 58
4.6.17. Seconary Heat Exchanger 59
4.6.18. Buffer Tank (“A” Series) 60
4.6.19. Circulation Pump (“A” Series) 61
4.6.20. Bypass Mixing Valve (“Non-A” Series) 62
5. TROUBLESHOOTING 63
5.1. ERROR CODE LIST 63
5.2. 01ERROR 65
5.3. 03ERROR 67
5.4. 04ERROR 75
5.5. 07ERROR 77
5.6. 08ERROR 79
5.7. 09ERROR 81
5.8. 10ERROR 84
5.9. 12ERROR 88
5.10. 15ERROR 91
5.11. 16ERROR 92

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5.12. 21ERROR 95
5.13. 22ERROR 96
5.14. 27ERROR 98
5.15. 30ERROR 100
5.16. 32ERROR 102
5.17. 33ERROR 103
5.18. 34ERROR 104
5.19. 35ERROR 107
5.20. 36ERROR 109
5.21. 37ERROR 110
5.22. 38ERROR 112
5.24. 44ERROR 117
5.25. 45ERROR 119
5.26. 48ERROR 122
5.27. TROUBLESHOOTING GUIDE BY SYMPTOM 124
5.27.1. Noise 124
5.27.2. Hot water 126
5.27.3. Circuit breaker operates 127
6. INSPECTION 128
6.1. PREPARING THE WATER HEATER FOR INSPECTION 128
6.2. MEASURING GAS PRESSURE SETTING 129
6.2.1. How to Check Inlet Gas Pressure 129
6.2.2. Adjusting the Gas-Air Ratio 130
7. MAINTENANCE 132
7.1. DRAINING THE WATER HEATER 132
7.2. CLEANING THE INTAKE AIR FILTER 133
7.3. FLUSHING THE HEAT EXCHANGER 134
8. REPLACEMENT OF PARTS 135
8.1. REPLACEMENT PROCEDURE 135
8.2. COMPONENTS REPLACEMENT INSTRUCTIONS 136
8.2.1. PCB 136
8.2.2. Fuse 137
8.2.3. Transformer 138
8.2.4. Fan Motor(Combustion Air Blow) 139
8.2.5. Flame Rod 140
8.2.6. Ignition Transformer 141
8.2.7. APS 142

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8.2.8. Manifold 143
8.2.9. Main Gas Valve 145
8.2.10. GPS 147
8.2.11. Condensation Trap 148
8.2.12. Water Adjustment Valve 149
8.2.13. Flow Sensor 150
8.2.14. Buffer Tank (“A” Series) 151
8.2.15. Circulation Pump (“A” Series) 152
8.2.16. 3-way Valve (“A” Series) 154
8.2.17. 2-way Valve (“NP-A” “NP” Series) 155
8.2.18. Bypass Mixing Valve (“Non-A” Series) 156
9. COMPONENTS DIAGRAM AND PART LIST 157
9.1. CASE DISASSEMBLE (NR/NP – A, NR/NP) 157
9.2. BURNER DISASSEMBLE (NR/NP – A, NR/NP) 159
9.3. WATER WAY DISASSEMBLE (NR-A) 162
9.4. WATER WAY DISASSEMBLE (NR) 163
9.5. WATER WAY DISASSEMBLE (NP-A) 164
9.6. WATER WAY DISASSEMBLE (NP) 165
10. INSPECTION AND MAINTENANCE SCHEDULE 169
10.1. ANNUAL SERVICING 169
10.2. INSPECTION REPORT 170
10.3. MAINTENANCE REPORT 171

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Revisions
Version Description of changes Date
1.00
2.00
First Issue
Format Revision
04/27/10
July/20/10

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Navien Warranty
APPLICABLE WARRANTY PERIODS (* DHW means Domestic Hot Water)
Period of Coverage
Heat Exchanger
NR & NP Series
Residential
*DHW use only
NP Series
Commercial use Or
Residential Space
Heating use
NP Series
Commercial use Or
Residential Space
Heating use
NR & NP Series
Residential
DHW use only
All other Parts and Components
15 years 10 years 5 years 3 years
GENERAL
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
replacement component part(s) must be Navien original factory component Part(s).
The replacement component part(s) will be warranted only for the unexpired portion
of the original component part’s Applicable Warranty Period.
CAUTION
This product warranty is valid only used in the America and Canada but automatically
be voided for the other counties (for America and Canada unit standard only).
IMPORTANT
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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HEAT EXCHANGER WARRANTY
The Applicable Warranty Period for a NR & NP series Heat Exchanger failure installed in a Resi-
dential DHW application (including domestic recirculation) is Fifteen (15) years from the Effective
Date. The Applicable Warranty Period for a NP series Heat Exchanger failure installed in a Com-
mercial application or Residential “Combi (DHW and Space heating)” application is Ten (10)
years from the Effective Date. For any Commercial application or Residential Combi application,
a NP series unit is recommended. If a NR series unit is used in any Commercial application or
Residential Combi application, the Applicable Warranty for a Heat Exchanger failure will be
voided.
PARTS WARRANTY (excluding heat exchanger)
The Applicable Warranty Period for a NR & NP series Part(s) failure installed in a Residential
DHW application (including domestic recircualtion) is Five(5) years from the Effective Date. The
Applicable Warranty Period for a NP series Part(s) failure installed in a Commercial application or
Residential Combi application is Three(3) years from the Effective Date. IF a NR unit is used in
any Commercial application or Residential Combi application, the Applicable Warranty for a
Part(s) failure will be voided.
WATER HEATER SHOULD NOT BE USED FOR
SPACE HEATING.(Only NR-(A) Series)
The NR Series Water Heater should not used for space Heating and other heating. If NR Series
Water Heater is used for space Heater and other heating, the applicable warranty will be voided.
LABOR ALLOWANCE
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.
TRANSFERABLILITY
This warranty is offered to the original and subsequent owners of the water heater but is limited
to the original address registered with the warranty only. The warranty will be void if the water
heater is relocated to any other location.
EFFECTIVE DATE
The Effective Date of warranty coverage (the beginning of the Applicable Warranty Periods) is the
date of purchase of this water heater, if properly registered.

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WARRANTY EXCLUSIONS
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.
This warranty does not cover the following conditions:
Damages, malfunctions, or failures resulting from failure to install the water heater 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 oper-
ate and maintain the water heater in accordance with the manufacturer’s instructions
provided.
•
Performance problems caused by improper sizing of the water heater or the gas supply
line, the venting connection, combustion air openings, electric service voltage, wiring or
fusing.
•
Damages, malfunctions or 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
water heater.
•
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 water heater in a corrosive or contami-
nated atmosphere.
•
Damages, malfunctions or failures 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 water heater 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 water heater should not be
operated if the rating plate has been removed.
•
Damage due to freezing.
•
Damages, malfunctions or failures caused by operating the water heater with any parts
removed or with parts that have been modified, altered or unapproved for installation.
•

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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
• 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 Water Heater.
About Notation in the Manual
Indication of Refer To
The “Ķ” mark is used to indicate the chapter or section you should refer to its format is
as indicated below.
Ķ{3.1 General Specification} of Ķ{3.1}


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Abbreviation and Definition
Abbreviation Definition
NR-A
NP-A
NR
NP
“A” Series
“Non-A” Series
NG
LP
AP
APS
DHW
FM
GARC
GPM
GPS
GV
MGV
MV
SGV
RPM
WAV
PCB
EMI
HTL
General name of NR-180A, NR-210A, and NR-240A
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
General name of NR-A, and NP-A
General name of NR, and NP
Natural Gas
Propane 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
Water Adjustment Valve
Printed Circuit Board
Electromagnetic Interface
High Temperature Limiter

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1. Safety Considerations
1.2. List of safety symbols in this manual
DANGER
WARNING
CAUTION
CAUTION
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.
1.3. Symbols Used in the Instructions
The following symbols are used throughout the instructions to bring attention to
important information concerning the appliance.
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.
1.1. Safety Definitions
All Safety messages will refer to potential hazards. Precisely follow the instructions
to avoid the risk of injury.
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.

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1.4. Safety Precautions
DANGER
FLAMMABLE MATERIALS
Keep the area around the water heater clear and free from flammable materials.
• DO NOT place flammable liquids such as oils or gasoline, etc. near the water
heater.
• DO NOT place combustibles such as newspapers and laundry etc. near the
water heater or the venting system.
• DO NOT place or use hair spray, spray paint or any other type of spray can
near the water heater 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 water heater such as a clothes line.
DANGER
Keep flammable
products:
far away from heater
in approved containers,
tightly closed, and out of
children’s reach.
Water heater 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.
FLAMMABLE VAPORS
Vapors from ammableliquidswill
explodeand catch re causing death or
severe burns.
Do notuse orstore ammableproducts
such as gasoline, solvents oradhesives in
thesameroom orarea near thewater
heater

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DANGER
COMPROMISED VENTING SYSTEM
Failure to follow the Venting Section of the installation manual may result in the
unsafe operation of this water heater. To avoid the risk of fire, explosion of
asphyxiation from carbon monoxide, never operate the water heater 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 water heater.
•
i. damaged in any way,
ii. have separated at a joint,
iii. are cracked or show evidence of corrosion, rusting or melting.
Immediately turn off and do not use the water heater if any of the vent pipes, vent
elbows and/or the water heater.
•
DANGER
HOT WATER TEMPERATURE SETTING
Water temperature over 125ȕcan cause severe burns
instantly or death from scalds.
•
Households with small children, disabled, or elderly
persons may require 120ȕor lower temperature setting to
prevent contact with “HOT” water.
•
To prevent scalding, check water temperature after servicing.
•
If the proposed water heater outlet temperature is above 125ı, 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.
•
This Navien Water Heater is factory se at 120ȕ(NP Series: 140ȕ) for your safety
and comfort. Increasing the set temperature increases the risk of accidental
scalding. Consult the chart below before you decide to adjust the set temperature.
•

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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 WATER HEATER.
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 Water Heater.
• This manual must remain with the Navien Water Heater.
• Confirm the location of the gas shut-off valve. Close the manual shut-off valve
if the Navien Water Heater over becomes subjected to overheating, fire, flood,
physical damage or any other such damaging condition during servicing.
• DO NOT turn on the water heater unless water and gas supplies are fully
opened.
• DO NOT turn on the water heater if cold water supply shut-off valve is closed.
• Make certain power to water heater 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
servicing.
• 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 afterservicing.
• DO NOT attempt to change the water temperature while someone is using the
water heater.
• DO NOT use parts other than those specified for this equipment.
• DO NOT operate the water heater 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
“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)” in the USA or the “National
Gas and Propane Installation Code (CAN/CSA B 149.1)” in Canada.
• Massachusetts code requires this water heater to be installed in accordance
with Massachusetts Plumbing and Fuel Gas Code 248 CMR Section 2.00 and
5.00.

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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
Water Heater to ensure the unit matches gas type, gas pressure, water pressure
and electrical supply.
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.
•
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
expectancy of this product.
•
If the unit does not match requirements, do not service, please contact
Navien immediately.
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.
Navien America Inc. is not liable for any property damage and/of personal
injury resulting from unauthorized conversions.
WARNING

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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. In addition, depending on the heat capacity, each model is divided
into three types; 180,210,and240(*).
Items
NP NR
“A” Series
(180/210/240)
“Non-A”
Series
(180/210/240)
“A” Series
(180/210/240)
“Non-A”
Series
(180/210/240)
Intended Use DHW Only
DHW
Space Heating
Commercial Applications
Built-in
Circulation Pump
and Mini Buffer Tank Yes No Yes No
Default
Temperature
120ȕ(49Ȕ) 140ȕ(60Ȕ)
Gas Type NG, LP
*.for details of the specifications, ೛{5.1 General Specifications}

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2.2. Layout and Key Components
2.2.1. NR-A Model
No Description Navien Part No. No Description Navien Part No.
1 Intake Air Duct BH2505400B 16 WAV NCVM9EX00005
2 Fan Motor NAFA9GLPCT01 17 Transformer BH1205008A
3 Buffer Tank PASNCWBFTANK_001 18 Exhaust Limit Switch BH1401027A
4 Flow Sensor BH1406004F 19 Secondary H/E -
5 PCB Board NACR1GS32410 20 Primary H/E -
6 Circulation Pump NAPU9GLPCT01 21 Ignition Transformer BH1201041D
7 DHW Supply Adapter BH2507348B 22 APS Venturi BH2501413A
8 3-Way Valve BH2507467C 23 Manifold PABCR180AMF_001
9 DHW Inlet Adapter BH2507469A 24 Burner PABNCN30KDBN_003
10 Syphon BH2507442C 25 APS NASS9EX00009
11 Gas Inlet Adapter BH2507396A 26 Exhaust Duct BH2544004F
12 Main Gas valve BH0901018A 27 Exhaust Pipe BH2505401B
13 GPS Venturi BH2507359B 28 Air Intake Guide BH2543002C
14 Gas Pipe BH2507509A 29 Power Switch BH1426002A
15 GPS NASS9EXGPS01 30 Water Leakage Detector -