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Navien NR-180A User Manual

Navien NR-180A
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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 +949-420-0420 FAX +949-420-0430
www.naviennamerica.com
MODEL
2
nd
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

Table of Contents

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Navien NR-180A Specifications

General IconGeneral
BrandNavien
ModelNR-180A
CategoryWater Heater
LanguageEnglish

Summary

REVISIONS

NAVIEN WARRANTY

HANDLING OF THIS MANUAL

ABBREVIATION AND DEFINITION

SAFETY CONSIDERATIONS

1.1. Safety Definitions

Defines safety terms and emphasizes following instructions to avoid hazards.

1.2. List of safety symbols in this manual

Lists and explains safety symbols used in the manual for hazard identification.

1.3. Symbols Used in the Instructions

Explains symbols used within the instructions to highlight important information.

1.4. Safety Precautions

Details crucial safety precautions related to flammable materials and vapors.

PRODUCT INFORMATION

2.1. Product Information

Overview of Navien Regular (NR) and Navien Premium (NP) series water heaters.

2.2. Layout and Key Components

Diagrams and lists of key components for different model series.

2.2.1. NR-A Model

Detailed layout and part numbers for the NR-A model.

2.2.2. NP-A Model

Detailed layout and part numbers for the NP-A model.

2.2.3. NR Model

Detailed layout and part numbers for the NR model.

2.2.4. NP Model

Detailed layout and part numbers for the NP model.

TECHNICAL DATA

3.1. General Specifications

Provides key specifications like heat capacity, dimensions, and gas type.

3.2. Dimensions

Illustrates connection diameters and overall dimensions.

3.2.1. NR-A, NP-A Model

Specific dimension details for NR-A and NP-A models.

3.2.2. NR, NP Model

Specific dimension details for NR and NP models.

SYSTEM DETAILS

4.1. Schematic and Flow Diagram

Visual representation of the system's water and gas flow.

4.1.1. NR-A Model

Schematic and flow diagram specific to the NR-A model.

4.1.2. NP-A Model

Schematic and flow diagram specific to the NP-A model.

4.1.3. NR Model

Schematic and flow diagram specific to the NR model.

4.2. Operation Flow Chart

Diagram illustrating the unit's operational sequence.

4.3. Dip Switch Settings

Configuration settings for dip switches on the PCB.

4.4. Wiring Diagram

Electrical wiring diagrams for different models.

4.4.1. NR-A Model

Wiring diagram for the NR-A model.

4.4.2. NP-A Model

Wiring diagram for the NP-A model.

4.4.3. NR Model

Wiring diagram for the NR model.

4.4.4. NP Model

Wiring diagram for the NP model.

4.5. Electrical Diagnostic Points

Identifies key points on the PCB for electrical diagnostics.

4.6. Key Components Description

Detailed descriptions of major components and their functions.

4.6.1. PCB

Description of the Printed Circuit Board (PCB) functions and failure events.

4.6.2. Thermal Fuse

Details on the thermal fuse, its function, and failure diagnostics.

4.6.3. Transformer

Information on the transformer's role in power supply and diagnostics.

4.6.4. High Limit Switch or Exhaust Limit Switch

Description of high limit and exhaust limit switches, including function and failure.

4.6.5. Thermistor

Details on thermistors for temperature measurement and error detection.

4.6.6. Fan motor

Explanation of the fan motor's function and troubleshooting steps.

4.6.7. Flame Rod Ass’y

Description of the flame rod assembly for ignition sensing.

4.6.8. Ignition Transformer

Information on the ignition transformer for spark generation.

4.6.9. APS

Details on the Air Pressure Sensor (APS) for airflow control.

4.6.10. Manifold

Description of the manifold's role in gas distribution.

4.6.12. GPS

Information on the Gas Pressure Sensor (GPS) for combustion control.

4.6.13. Burner

Description of the burner assembly and its combustion function.

4.6.14. Water Adjustment Valve

Explanation of the water adjustment valve for flow control.

4.6.15. Flow Sensor

Details on the flow sensor for measuring water flow rate.

4.6.16. Primary Heat Exchanger

Description of the primary heat exchanger's function.

4.6.17. Secondary Heat Exchanger

Description of the secondary heat exchanger's function.

4.6.18. Buffer Tank (“A” Series)

Details on the buffer tank for temperature stability in 'A' series.

4.6.19. Circulation Pump (“A” Series)

Explanation of the circulation pump in 'A' series for hot water circulation.

4.6.20. Bypass Mixing Valve (“Non-A” Series)

Description of the bypass mixing valve for temperature control.

TROUBLESHOOTINGData

5.1. Error Code List

List of error codes with their reasons and diagnostic actions.

5.2. 01Error

Details on '01Error' related to heat exchanger boiling.

5.3. 03Error

Troubleshooting for '03Error' indicating ignition failure.

5.4. 04Error

Troubleshooting for '04Error' related to false flame detection.

5.6. 08Error

Troubleshooting for '08Error' related to hot water temperature sensor short-circuit.

5.7. 07Error

Troubleshooting for '07Error' related to hot water temperature sensor open.

5.7. 09Error

Troubleshooting for '09Error' related to fan motor RPM error.

5.8. 10Error

Troubleshooting for '10Error' indicating air pressure error.

5.9. 12Error

Troubleshooting for '12Error' related to loss of flame during combustion.

5.10. 15Error

Troubleshooting for '15Error' indicating internal PCB error.

5.11. 16Error

Troubleshooting for '16Error' related to bimetal overheating.

5.12. 21Error

Troubleshooting for '21Error' indicating heat exchanger input sensor open.

5.13. 22Error

Troubleshooting for '22Error' indicating heat exchanger input sensor short-circuit.

5.14. 27Error

Troubleshooting for '27Error' related to air volume sensor error.

5.15. 30Error

Troubleshooting for '30Error' related to exhaust gas temperature error.

5.16. 32Error

Troubleshooting for '32Error' related to direct water temperature sensor open.

5.17. 33Error

Troubleshooting for '33Error' related to direct water temperature sensor short-circuit.

5.18. 34Error

Troubleshooting for '34Error' indicating water adjustment valve error.

5.19. 35Error

Troubleshooting for '35Error' related to gas pressure sensor error.

5.20. 36Error

Troubleshooting for '36Error' indicating communication error.

5.21. 37Error

Troubleshooting for '37Error' related to internal water leak.

5.22. 38Error

Troubleshooting for '38Error' indicating pump error.

5.23. 39Error

Troubleshooting for '39Error' related to flow sensor error.

5.24. 44Error

Troubleshooting for '44Error' related to temperature sensor connection error.

5.25. 45Error

Troubleshooting for '45Error' indicating bypass mixing valve error.

5.26. 48Error

Troubleshooting for '48Error' related to gas pressure error.

5.27. Troubleshooting guide by symptom

Guides for troubleshooting issues based on specific symptoms.

5.27.1. Noise

Diagnosing and resolving various types of noise from the unit.

5.27.2. Hot water

Troubleshooting common hot water related issues.

5.27.3. Circuit breaker operation

Steps to troubleshoot circuit breaker trips.

INSPECTION

6.1. Preparing the Water heater for Inspection

Lists precautions and tools required for water heater inspection.

6.2. Measuring Gas Pressure Setting

Procedure for measuring and setting gas pressure.

6.2.1. How to Check Inlet Gas Pressure

Detailed steps for checking the inlet gas pressure.

6.2.2. Adjusting the Gas-Air Ratio

Instructions for adjusting the gas-air ratio for optimal combustion.

MAINTENANCE

7.1. Draining the Water heater

Procedure for draining water from the unit and cleaning the filter.

7.2. Cleaning the Intake Air Filter

Instructions for cleaning the intake air filter.

7.3. Flushing the Heat Exchanger

Procedure for flushing the heat exchanger with a cleaning solution.

REPLACEMENT OF PARTS

8.1 Replacement Procedure

General safety precautions and procedures for replacing parts.

8.2. Components Replacement Instructions

Step-by-step instructions for replacing key components.

8.2.1. PCB

Procedure for replacing the Printed Circuit Board (PCB).

8.2.2. Fuse

Procedure for replacing the fuse.

8.2.3. Transformer

Procedure for replacing the transformer.

8.2.4. Fan Motor(Combustion Air)

Procedure for replacing the fan motor.

8.2.5. Flame Rod

Procedure for replacing the flame rod assembly.

8.2.6. Ignition Transformer

Procedure for replacing the ignition transformer.

8.2.7. APS

Procedure for replacing the Air Pressure Sensor (APS).

8.2.8. Manifold

Procedure for replacing the manifold assembly.

8.2.9. Main Gas Valve

Procedure for replacing the main gas valve.

8.2.10. GPS

Procedure for replacing the Gas Pressure Sensor (GPS).

8.2.11. Condensation Trap

Procedure for replacing the condensation trap.

8.2.12. Water Adjustment Valve

Procedure for replacing the water adjustment valve.

8.2.13. Flow Sensor

Procedure for replacing the flow sensor.

8.2.14. Buffer Tank (“A” Series)

Procedure for replacing the buffer tank in 'A' series units.

8.2.15. Circulation Pump (“A” Series)

Procedure for replacing the circulation pump in 'A' series units.

8.2.16. 3-way Valve (“A” Series)

Procedure for replacing the 3-way valve in 'A' series units.

8.2.17. 2-way Valve (“NP-A” “NP” Series)

Procedure for replacing the 2-way valve in NP-A/NP series.

8.2.18. Bypass Mixing Valve (“Non-A” Series)

Procedure for replacing the bypass mixing valve in 'Non-A' series.

Components Diagram and Part List

9.1. Case Disassemble (NR/NP – A, NR/NP)

Diagram and steps for disassembling the unit's case.

9.2. Burner Disassemble (NR/NP – A, NR/NP)

Diagram and steps for disassembling the burner assembly.

9.3. Water Way Disassemble (NR-A)

Diagram for disassembling the water way components of the NR-A model.

9.4. Water Way Disassemble (NR)

Diagram for disassembling the water way components of the NR model.

9.5. Water Way Disassemble (NP-A)

Diagram for disassembling the water way components of the NP-A model.

9.5. Water Way Disassemble (NP)

Diagram for disassembling the water way components of the NP model.

Inspection and maintenance Schedule

10.1. Inspection Report

Template for recording annual inspection results.

10.2. Inspection Report

Checklist items for visual inspection and system checks.

10.3. Maintenance Report

Checklist items for routine maintenance tasks.

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