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Navien NR-240 Service Manual

Navien NR-240
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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-240 Specifications

General IconGeneral
BrandNavien
ModelNR-240
CategoryWater Heater
LanguageEnglish

Summary

Revisions

Navien Warranty

Warranty Caution

Safety warning regarding warranty validity outside North America.

General Warranty Terms

States Navien's warranty for materials and workmanship under normal use.

Applicable Warranty Periods

Details coverage periods for heat exchangers and other parts.

Warranty Proof of Purchase

Specifies proof of purchase requirements for warranty service.

Handling of This Manual

Manual Scope

Defines the applicability of the service manual to Navien Tankless Water Heater NR/NP Series.

Manual Handling Precautions

Outlines important guidelines for manual accessibility and understanding.

Manual Notation Explanation

Explains symbols and notations used within the manual for clarity.

Abbreviation and Definition

Safety Considerations

Safety Definitions

Defines potential hazards and emphasizes following instructions to avoid injury.

List of Safety Symbols

Lists and explains various safety symbols used in the manual.

Symbols Used in Instructions

Explains symbols used to highlight important information in the instructions.

Safety Precautions

Flammable Materials Handling

Instructions to keep the area around the water heater clear of flammable materials.

Flammable Vapors Warning

Warning about explosion risk from flammable vapors near the water heater.

Compromised Venting System Safety

Emphasizes proper venting to prevent fire, explosion, or asphyxiation.

Hot Water Temperature Setting Safety

Advises on safe hot water temperatures to prevent scalding.

Gas Leak Safety Procedure

Provides critical steps to follow in case of a gas leak.

Important Safety Guidelines

Lists essential safety guidelines before operating or servicing the unit.

Installation Requirement Compliance

Highlights the need to follow local codes and manufacturer instructions for installation.

Gas Type and AC Voltage Verification

Advises checking gas type and AC voltage compatibility before servicing.

Gas Conversion Warning

Warns against field conversion and its warranty implications.

Product Information

Product Series Overview

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

Layout and Key Components

NR-A Model Layout

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

NP-A Model Layout

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

NR Model Layout

Details the layout and part numbers for the NR model.

NP Model Layout

Details the layout and part numbers for the NP model.

Technical Data

General Specifications

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

NR-A, NP-A Model Dimensions

Shows the physical dimensions and connection diameters for NR-A/NP-A.

NR, NP Model Dimensions

Shows the physical dimensions and connection diameters for NR/NP.

System Details

NR-A Model Schematic and Flow Diagram

Illustrates the internal workings and flow paths of the NR-A model.

NP-A Model Schematic and Flow Diagram

Illustrates the internal workings and flow paths of the NP-A model.

NR Model Schematic and Flow Diagram

Illustrates the internal workings and flow paths of the NR model.

NP Model Schematic and Flow Diagram

Illustrates the internal workings and flow paths of the NP model.

Operation Flow Chart

Visual representation of the unit's operational sequence.

Dip Switch Settings

Explains the function and configuration of PCB dip switches.

NR-A Model Wiring Diagram

Wiring diagram for the NR-A model.

NP-A Model Wiring Diagram

Wiring diagram for the NP-A model.

NR Model Wiring Diagram

Wiring diagram for the NR model.

NP Model Wiring Diagram

Wiring diagram for the NP model.

Key Components Description

PCB Functionality

Describes the function, failure events, error codes, and diagnostics of the PCB.

Thermal Fuse Operation

Details the thermal fuse's role in protecting the unit from overheating.

Transformer Functionality

Explains the transformer's function in supplying power to the PCB and components.

High Limit Switch Function

Describes the function of safety switches that prevent overheating.

Thermistor Functionality

Explains thermistors' role in measuring temperatures and detecting failures.

Fan Motor Function

Details the fan motor's function in providing combustion air and exhausting flue gas.

Flame Rod Assembly

Describes the flame rod's function in detecting ignition and flame presence.

Ignition Transformer Function

Explains the ignition transformer's role in generating spark for ignition.

APS Functionality

Details the Air Pressure Sensor's function in controlling air supply for combustion.

Manifold Functionality

Describes the manifold's function in distributing gas to the burners.

Main Gas Valve Function

Explains the main gas valve's role in controlling gas supply to the unit.

GPS Functionality

Details the Gas Pressure Sensor's function in modulating gas supply for stable combustion.

Burner Functionality

Describes the burner's function in mixing gas and air for combustion.

Water Adjustment Valve Function

Explains the valve's function in controlling water flow for temperature regulation.

Flow Sensor Functionality

Details the flow sensor's role in measuring water flow rate.

Primary Heat Exchanger

Describes the primary heat exchanger's function in heat transfer.

Secondary Heat Exchanger

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

Buffer Tank ('A' Series)

Details the buffer tank's function in providing steady hot water temperature.

Circulation Pump ('A' Series)

Explains the circulation pump's role in internal/external hot water circulation.

Bypass Mixing Valve ('Non-A' Series)

Describes the valve's function in modulating outlet water temperature.

Troubleshooting

Error Code List

Lists error codes, their reasons, and diagnostic/reset actions.

01Error Troubleshooting

Details error conditions, description, and check items for 01Error (Boiling).

03Error Troubleshooting

Explains error conditions, description, and check items for 03Error (Ignition Fail).

04Error Troubleshooting

Details error conditions, description, and check items for 04Error (False-flame detection).

07Error Troubleshooting

Explains error conditions, description, and check items for 07Error (Hot water temperature sensor open).

08Error Troubleshooting

Details error conditions, description, and check items for 08Error (Short-circuit of hot water temperature sensor).

09Error Troubleshooting

Explains error conditions, description, and check items for 09Error (Fan motor RPM error).

10Error Troubleshooting

Details error conditions, description, and check items for 10Error (Air pressure error).

12Error Troubleshooting

Explains error conditions, description, and check items for 12Error (Loss of flame during combustion).

15Error Troubleshooting

Details error conditions, description, and check items for 15Error (MICOM error).

16Error Troubleshooting

Explains error conditions, description, and check items for 16Error (Bimetal overheated).

21Error Troubleshooting

Details error conditions, description, and check items for 21Error (Heat exchanger input temperature sensor open).

22Error Troubleshooting

Explains error conditions, description, and check items for 22Error (Heat exchanger input temperature sensor shortcircuit).

27Error Troubleshooting

Details error conditions, description, and check items for 27Error (Air volume sensor error).

30Error Troubleshooting

Explains error conditions, description, and check items for 30Error (Exhaust gas temperature error).

32Error Troubleshooting

Details error conditions, description, and check items for 32Error (Direct water temperature sensor open).

33Error Troubleshooting

Explains error conditions, description, and check items for 33Error (Direct water temperature sensor short-circuit).

34Error Troubleshooting

Details error conditions, description, and check items for 34Error (Water Adjustment Valve error).

35Error Troubleshooting

Explains error conditions, description, and check items for 35Error (Gas pressure sensor error).

36Error Troubleshooting

Details error conditions, description, and check items for 36Error (Communication Error).

37Error Troubleshooting

Explains error conditions, description, and check items for 37Error (Internal water leak).

38Error Troubleshooting

Details error conditions, description, and check items for 38Error (Pump error).

39Error Troubleshooting

Explains error conditions, description, and check items for 39Error (Flow sensor error).

44Error Troubleshooting

Details error conditions, description, and check items for 44Error (Temperature sensor connection error).

45Error Troubleshooting

Explains error conditions, description, and check items for 45Error (Bypass Mixing Valve error).

48Error Troubleshooting

Details error conditions, description, and check items for 48Error (Gas pressure error).

Troubleshooting Guide by Symptom

Noise Troubleshooting

Guides troubleshooting for various types of noise issues.

Hot Water Problems

Provides troubleshooting steps for problems related to hot water supply.

Circuit Breaker Operation Issues

Addresses troubleshooting steps when the circuit breaker operates.

Inspection

Preparing for Inspection

Lists necessary precautions and tools for performing an inspection.

How to Check Inlet Gas Pressure

Step-by-step guide for checking the inlet gas pressure.

Adjusting the Gas-Air Ratio

Detailed procedure for adjusting the gas-air ratio for optimal combustion.

Maintenance

Draining the Water Heater

Instructions for draining water from the unit and cleaning the inlet filter.

Cleaning the Intake Air Filter

Procedure for cleaning the intake air filter.

Flushing the Heat Exchanger

Steps for flushing the heat exchanger to maintain performance.

Replacement of Parts

General Replacement Procedure

General guidelines and safety precautions for replacing parts.

Components Replacement Instructions

Detailed instructions for replacing individual components.

PCB Replacement Guide

Step-by-step guide for replacing the Printed Circuit Board (PCB).

Fuse Replacement Instructions

Instructions for replacing the fuse.

Transformer Replacement Guide

Detailed steps for replacing the transformer.

Fan Motor Replacement Guide

Guide for replacing the fan motor responsible for combustion air.

Flame Rod Replacement Guide

Instructions for replacing the flame rod assembly.

Ignition Transformer Replacement Guide

Steps for replacing the ignition transformer.

APS Replacement Guide

Guide for replacing the Air Pressure Sensor (APS).

Manifold Replacement Guide

Detailed instructions for removing and replacing the manifold.

Main Gas Valve Replacement Guide

Steps for replacing the main gas valve.

GPS Replacement Guide

Guide for replacing the Gas Pressure Sensor (GPS).

Condensation Trap Replacement Guide

Instructions for replacing the condensation trap.

Water Adjustment Valve Replacement Guide

Steps for replacing the water adjustment valve.

Flow Sensor Replacement Guide

Guide for replacing the flow sensor.

Buffer Tank ('A' Series) Replacement

Instructions for replacing the buffer tank on 'A' Series models.

Circulation Pump ('A' Series) Replacement

Steps for replacing the circulation pump on 'A' Series models.

3-way Valve ('A' Series) Replacement

Instructions for replacing the 3-way valve on 'A' Series models.

2-way Valve ('NP-A'/'NP' Series) Replacement

Steps for replacing the 2-way valve on NP-A/NP Series.

Bypass Mixing Valve ('Non-A' Series) Replacement

Instructions for replacing the bypass mixing valve on 'Non-A' Series.

Components Diagram and Part List

Case Disassembly Guide

Illustrates the process of disassembling the unit's case.

Burner Disassembly Guide

Shows the steps for disassembling the burner assembly.

NR-A Water Way Disassembly

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

NR Water Way Disassembly

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

NP-A Water Way Disassembly

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

NP Water Way Disassembly

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

Inspection and Maintenance Schedule

Inspection Report Overview

Summarizes the recommended annual inspection items.

Detailed Inspection Report Form

Provides a checklist for annual inspection items.

Detailed Maintenance Report Form

Provides a checklist for maintenance procedures.

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