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Navien CH-240 Service Manual

Navien CH-240
155 pages
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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 +949-420-0420 FAX +949-420-0430
www.naviennamerica.com
1
st
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.

Table of Contents

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Navien CH-240 Specifications

General IconGeneral
Gas Connection3/4" NPT
Water Connection3/4" NPT
TypeCondensing Tankless
Fuel TypeNatural Gas or Propane
Voltage120V
Temperature Range98°F - 140°F
Vent Diameter3" PVC/CPVC
Warranty15 years heat exchanger, 5 years parts

Summary

Revisions

Navien Warranty

Handling of this manual

Abbreviation and definition

Safety Considerations

Safety Definitions

Definitions of hazard terms used in the manual.

List of safety symbols in this manual

Explains hazard symbols like DANGER, WARNING, CAUTION.

Symbols Used in the Instructions

Explains symbols for IMPORTANT and NOTE.

Safety Precautions

General safety guidelines for operation and environment.

Product Information

Product Information

Overview of the Navien condensing gas boiler features and models.

Layout and Key Components

Identifies and lists major internal components with part numbers.

Technical Data

General Specifications

Provides key technical specifications for different models.

Dimensions

Shows physical dimensions and connection diameters.

System Details

Schematic and Water Flow Diagram

Illustrates water flow for heating and DHW modes.

Operation Flow Chart

Visualizes the boiler's operational sequence and logic.

Dip Switch Settings

Details the function and configuration of DIP switches.

Wiring Diagram

Provides a detailed electrical wiring schematic.

Electrical Diagnostic Points

Identifies key test points for electrical troubleshooting.

PCB

Describes the Printed Circuit Board (PCB) function and failure.

Transformer

Explains the function and specifications of the transformer.

High Limit Switch or Exhaust Limit Switch

Details the function of limit switches for overheat protection.

Thermistor

Explains the function and types of thermistors used.

Fan motor

Describes the fan motor's role in combustion air supply.

Flame Rod Ass’y

Details the flame rod's function in ignition and flame detection.

Ignition Transformer

Explains the ignition transformer's role in spark generation.

APS

Describes the Air Pressure Sensor's function in air supply control.

Manifold

Explains the manifold's role in gas distribution to the burner.

Main Gas Valve

Details the main gas valve's function in controlling gas flow.

GPS

Explains the Gas Pressure Sensor's role in combustion control.

Burner

Describes the burner assembly and its function in combustion.

DHW Flow Sensor

Explains the flow sensor's function in steady hot water temperature.

Primary Heat Exchanger

Details the primary heat exchanger's role in heat transfer.

Secondary Heat Exchanger

Explains the secondary heat exchanger's function in heat transfer.

DHW Heat Exchanger

Describes the DHW heat exchanger's role in hot water generation.

Circulation Pump

Explains the circulation pump's function in water circulation.

3-Way Valve

Details the 3-way valve's function in switching between heating and DHW.

Water pressure Sensor

Explains the water pressure sensor's role in system operation.

Auto Feeder Valve

Describes the auto feeder valve's function in maintaining water pressure.

Troubleshooting

Error Code List

Comprehensive list of error codes and their reasons.

01Error

Troubleshooting steps for 'Boiling' error.

03Error

Troubleshooting steps for 'Ignition failure'.

04Error

Troubleshooting steps for 'False-flame detection'.

05Error

Troubleshooting steps for 'Disconnection of supply temperature sensor'.

06Error

Troubleshooting steps for 'Shortcircuit of heating temperature sensor'.

07Error

Troubleshooting steps for 'Hot Water Outlet thermistor open error'.

08Error

Troubleshooting steps for 'Hot Water outlet thermistor short'.

09Error

Troubleshooting steps for 'Fan Motor RPM error'.

10Error

Troubleshooting steps for 'Air pressure Sensor error'.

11Error

Troubleshooting steps for 'Water pressure sensor error'.

12Error

Troubleshooting steps for 'Flame loss'.

15Error

Troubleshooting steps for 'PCB error'.

16Error

Troubleshooting steps for 'High Limit Switch Cut-off'.

18Error

Troubleshooting steps for 'Space heating return thermistor open'.

19Error

Troubleshooting steps for 'Short circuit of space heating return thermistor'.

21Error

Troubleshooting steps for 'Cold water inlet thermistor open'.

22Error

Troubleshooting steps for 'Shortcircuit of cold water inlet thermistor'.

27Error

Troubleshooting steps for 'Abnormal air pressure sensor error'.

28Error

Troubleshooting steps for 'Leakage'.

30Error

Troubleshooting steps for 'Exhaust high limit error'.

35Error

Troubleshooting steps for 'Gas pressure sensor error'.

36Error

Troubleshooting steps for 'Communication error'.

39Error

Troubleshooting steps for 'Flow sensor error'.

40Error

Troubleshooting steps for 'Short circuit of outdoor temperature sensor'.

Troubleshooting guide by symptom

Guides troubleshooting based on symptoms like noise or hot water issues.

Inspection

Preparing the Boiler for Inspection

Lists precautions and tools for boiler inspection.

Measuring Gas Pressure Setting

Procedures for checking and adjusting gas pressure.

Maintenance

Draining the Combination Water Heater / Boiler

Steps for draining water from the unit.

Cleaning the Intake Air Filter

Instructions for cleaning the air filter.

Replacement of Parts

Replacement Procedure

General safety and procedural guidelines for part replacement.

Components Replacement Instructions

Detailed steps for replacing individual components.

Components Diagram and Part List

Case Disassemble

Steps for disassembling the boiler's outer casing.

Burner Disassemble

Diagram and list for burner assembly parts.

Water Way Disassemble

Diagram and list for water pathway components.

Inspection and maintenance Schedule

Annual Servicing

Recommended annual inspection and maintenance tasks.

Inspection Report

A template for recording inspection findings.

Maintenance Report

A template for recording maintenance performed.

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