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Service Manual - Boston Heating Supply

1. Does the water heater have sufficient gas pressure d Check the gas pressure Gas Pressure NG 6 10 5 w c LP 813 5 w c Yes Check the burner assembly flame rod and gas valve assembly 82 ONavien America Inc 2010 CH series service Manual Version 1 0 Check method Thudding noise caused by minimum flow Possible Causes Defective circulation pump Check method 1 Check the gas supply pressure Y NG 6 10 5 W C LP 8 13 5 W C Y LPG pressure drop occurs frequently in the winter 2 Check the Gas Pipe Diameter 3 4 or wider 3 While the static pressure is normal a large difference of dynamic pressure may cause drop of gas pressure Therefore it is required to check the dynamic pressure 4 Check the gas pipe connector V Excessive force in fastening nuts at installation of gas pipe may move the packing and block the Teflon sealing causing a drop of gas supply pressure 5 Check the Gas meter Capacity PCB capacity setting error Check the PCB DIP S W capacity setting Flame blowout and noise occurs after ignition Off at switch of stage Flame blowout and noise Differential gas pressure adjustment error Defective air pressure sensor Debris in the nozzle Defective multistage valve Defective proportional valve in the main gas valve 3 stage MIN differential gas adjustment error y Adjust PCB DIP S W 1 2 ON in t
2. 112 6 1 PREPARING THE BOILER FOR INSPECTION 112 6 2 MEASURING GAS PRESSURE SETTING aiiis 113 6 2 1 How to Check Inlet Gas Pressure eee 113 627 AgdUSHHO T8 CIS AU EE 114 7 MAINTENANCE e enne 116 7 1 DRAINING THE BOILER s 116 72 CLEANING THE INTAKE AIR FILTER t 117 7 3 FLUSHING THE HEAT EXCHANGER 7 7 7 7 7 7 7 7 7 n 117 8 REPLACEMENT OF PARTS 7 7 7 emen 118 8 1 REPLACEMENT PROCEDURE 7 77 7 emen 118 8 2 COMPONENTS REPLACEMENT INSTRUCTIONS 7 119 Ba S WE 119 82 2 FUSE E 120 823 EE ee 121 98 2 4 Fan Motor COMPDUSION AI iai 122 0 2 0 Fame ROQ eener 123 8 2 6 Ignition Rn et 124 8 2 7 APS 0 o 125 Ee WEE 126 8 2 9 Main Gas VMA VO nac 127 8 2 10 GPS A eta eB 129 8 2 11 Condensation Trap prn MEME RR 130 8 2 12 Flow Sensor 131 8 2 13 Circulation Pump P M eege 132 EE 133 8 2 15 Water Pressure Sensor o e A e e o AT 134 3 ONavie
3. 4 6 10 Manifold Navien Part No PABNR NP180AMF 001 PABCR180AMF 001 PABCC210AMF 001 Check Point PABCC210AMF 002 Function Failure Event 1 The manifold distributes gas from the gas valve to the burner 2 To provide proper quantity of gas to burner in each stage 3 There are 3 zones within the manifold to ensure efficient combustion operation 1 Dust deposit on the manifold 2 Gas leakage from a failed manifold 3 Ignition failure 4 Imperfect combustion Effects 1 The burner cannot receive proper gas flow from the manifold which can cause poor combustion in the combustion chamber In this case the flame rod will detect an improper flame condition and the PCB board will take safety measures 2 Gas leakage from the manifold Error Code Diagnostic E003 E004 E012 1 Visual inspection Connection and or breakage of wires 2 Voltage check Check range of voltage shown below Color Number of wires 1 Yellow Yellow On DC 83 120 V Off 0 V 2 Red Red On DC 83 120 V Off 0 V Model 180 NG PG 1 Stage 60 138 x 1 00 087 C GAMA A O 9 WO Oy Oy P z S gt gt A pl i S i Navien America Inc 2010 2 Stage 00 138 x 1 00 087 3 Stage 00 112 x 3 00 069 Model 210 240 oF Solenoid Valve So AW gg Fuel Gas Supply 00 111 x2 0 111 x2 we 42
4. 13 Replace the flow sensor refer to Figure 51 8 2 12 Flow Sensor 8 Loosen the domestic hot water outlet 14 Replace the PCB refer to 8 2 1 adaptor 2 screw from bottom base PCB 16 Install front panel using 4 four screws 17 Turn on water supply power supply and gas supply 18 Open a hot water tap and ensure there are no leaks at the boiler Figure 52 138 ONavien America Inc 2010 CH series service Manual Version 1 0 9 Components Diagram and Part List 9 1 Case Disassemble 139 ONavien America Inc 2010 CH series service Manual Version 1 0 Description Navien Part No Remark Case BBK05011089 Cover BBR15012136 Emblem BH2603008A Case Upper Bracket BH2505277A Case Lower Bracket Deco BBK05197001 BH2602012A Pressure Indicator Intake Air Duct Ass y BH2505400B Intake Air Duck Packing No 6 Ass y Exhaust Pipe Ass y BH2505401B Exhaust Pipe O Ring No 7 Ass y Exhaust Pipe Packing No 7 Ass y Intake Air Filter BH2505416A Intake Air Filter Support BH2505417A Transformer BH1205011C PCB Board Power Switch PCB Board Bracket Upper PCB Board Bracket Lower NACR1GS32301 BH2505413A BH2505414A BH1426002A Screw D4 x 8L BH1705007A Bolt M4 x 16L BH1603009A Screw D4 x 12L Bolt D4 x 10L STS ONavien America Inc 2010 BH1612005A BH1611006A 140 CH series service Manu
5. 8 2 8 Manifold Figure 24 9 Remove the main gas valve screws from the gas adapter FUEL GAS INLET Kl Figure 25 10 Pull out the main gas valve 11 Positioned main gas valve 12 Attach the main gas valve and secured with screws 13 Assemble the air pressure feedback tube gas pressure sensor tube and wire harness connector 128 14 Replace the gas pipe Replace the Oring where the assembly attaches to the gas connection Make sure the old Oring removed and discarded N WARNING Failure to correctly assemble the components according to these instructions may result in a gas leak or explosion Tos 16 17 18 19 Figure 20 Replace the PCB refer to 8 2 1 PCB Install front panel using 4 four screws Turn on water supply power supply and gas supply Perform the measuring of gas pres sure setting procedure Check for gas leaks NOTE 1 Always replace with new gasket 2 Wiring should be in right position 3 Always use right part Oring and right size and place to pipe ONavien America Inc 2010 CH series service Manual Version 1 0 8 2 10 GPS Turn off the gas supply 2 Turn off the 120V power supply 3 Turn off the water supply 4 Remove the four screws securing the front panel Remove front panel 5 Remove the gas pressure sensor connecting housing into the PCB Figure 28 9 Replace with new gas pressure sensor 10 Assemb
6. 2 Burner Operation Mode Select DIP Switch Operation Mode Maximum Operation Minimum Operation 3 Stage Minimum 1 amp 2 Burner Operation Mode Select DIP S W 1 2 CH 240 CH 240 ASME 26 ONavien America Inc 2010 CH series service Manual Version 1 0 Set of 8 Switches Operation Mode Selection DIP S W Description No Function ON OFF Ready Link Ready Link Multi System Select Multi System Master Normal System 3 External Thermostat Using External Non Using External 4 Select Ther mostat Thermostat Space Heating Return Supply Temperature Control Temperature Control Temperature Control Space Heating Temperature 1 Refer to next page 4 amp 5 1 2 5 6 Space Heating Temperature 2 7 DHW Temperature 1 Refer to next page 7 amp 8 8 DHW Temperature 2 27 Navien America Inc 2010 CH series service Manual Version 1 0 4 amp 5 amp 6 Space Heating Used Only Supply Return Temperature Selection DIP Switch Temperature 5 OFF 120 F 49 C 160 F 71 C 180 F 82 C 95 F 35 C 110 F 43 C ON 125 F 51 C OFF 140 F 60 C ON OFF ON 49 C 140 F 60 C ON 71 C 82 C 7 amp 8 DHW Used Only Hot Water Temperature Selection DIP Switch Temperature The dip switch 7 to the right of the set of 8 which is used only for organizing cascade system
7. CH series service Manual Version 1 0 4 6 11 Main Gas Valve Navien Part No BH0901018A Check Point BEEF 1 To control the amount of supply gas by electronically following the main l PCB board Function 2 To maximize combustion main gas valve harmonized with GPS 3 When some disorders occur for the inadequate combustion it shuts off the gas valve automatically and prevents unsafe situations 1 Gas leak from the valves Failure Event 2 Unable to open close main and solenoid gas valve 3 Unable to modulate the gas flow proportional gas valve 1 Gas leak from the unit 2 No flames Effects 3 No operation of the unit 4 Excess carbon monoxide emissions Error Code E003 E012 E035 E048 1 Visual inspection Connection and or breakage of wires Diagnostic clunk sounds from the gas valves opening 2 Voltage check Check range of voltage shown below Color 1 Brown brown ON DC83 120 V OFF 0 V Number of wires 2 Yellow yellow ON DC83 120 V OFF 0V 3 Red red ON DC83 120 V OFF 0V KO T Tsj Gas Flow Diagram 43 ONavien America Inc 2010 CH series service Manual Version 1 0 4 6 12 GPS 1 Sensing the gas pressure for gas velocity to control combustible air supply 2 GPS device automatically detects the quantity of gas supply in any Functi
8. and if it is open 3 Check the grounding to the base verify grounding at the outlet V There is a case of defective grounding due to the painting of Flame sensing cabinet Therefore remove the painting in the screw fastening error part and reconnect Verify outlet is grounded properly 4 Check the flame sensing current Repeated V Or use a tester to measure the flame sensing current 1 20 yA ignition failure after ignition ok Grounding wire Measuring flame current fixing position 1 The APS hose is broken i V Increased RPM may cause flame lifting and noise Detective VY 10E may occur with the same trouble lifting and noise APS hose 2 Check if the hose is clogged with water remained from installa tion occurs at ignition The system works but combustion is not normal due to the defective APS Flame 66 ONavien America Inc 2010 CH series service Manual Version 1 0 lt Defective APS hose gt PCB DIP S W model setting error Incorrect DIP S W setting per model on the PCB may cause a problem on ignition and combustion Adjust differential pressure to MIN between 3 stages with the gas manometer 17mmH O 1 refer to 6 2 2 Adjusting the Gas Air Ratio Adjust gas 4 E He adjusting screw under the gas block 75 turn and Y When an ignition failure occurs due to a problem in supplying gas or adjusting gas pressure cover the blower inlet hole with a hand at the ignition stage If a flam
9. system inside the unit Figure 39 23 Open air vent on top of pump to 9 Loosen the heating adaptor 2 screw release air from bottom base NOTE 1 Always use right part O ring and right size and place to pipe 2 Place black gasket ring on top of the circulation pump and screw on the stainless nut be sure not to cross thread over tightening may damage gasket 8 2 14 3 way Valve 1 Turn off the gas supply Figure 40 2 Turn off the 120V power supply 10 Pull out the 3 way 3 Turn off the water supply Drain all water include heating water from the appliance 4 Remove the four screws securing the front panel Remove front panel 5 Pull out the PCB refer to 8 2 1 PCB 6 Pull out the circulation pump refer to 8 2 13 Circulation Pump 7 Loosen the heating water inlet pipe ll screw from 3 way valve 133 ONavien America Inc 2010 CH series service Manual Version 1 0 11 Replace with new 3 way valve 12 Tighten the heating adaptor 2 screw from bottom base 13 Tighten the heating water inlet pipe Il screw 14 Replace the stainless clip fastener E 12 Install front panel using 4 four screws 13 Turn on water supply power supply and gas supply 14 Open a hot water tap and ensure there are no leaks at the boiler 8 2 15 Water Pressure Sensor 1 Turn off the gas supply 2 Turn off the 120V power supply 3 Turn off the water supply Drain all water include heating water from th
10. 1 0 10 3 Maintenance Report Inspection Items References Draining the Boiler and Cleaning the Inlet Water Filter YES NO Cleaning the Return Filter YES NO Checking the Intake Air Filter YES NO o Flushing the Heat Exchanger YES NO Replacement of Parts 149 ONavien America Inc 2010 CH series service Manual Version 1 0 d Memo 150 ONavien America Inc 2010 CH series service Manual Version 1 0 d Memo 151 ONavien America Inc 2010 CH series service Manual Version 1 0 d Memo 152 ONavien America Inc 2010 CH series service Manual Version 1 0
11. Check the vent pipe for obstructions i Automatic air pressure sensor Check and clean the air filter Water leak pipe line Check pipe line Manual Exhaust Overheat exhaust high limit switch shuts down the unit when the flue temperature exceed 149 F 65 C Clean the inlet water filter Check the heat exchanger flush with a cleaning solution Automatic Measure gas pressure drop Check hose connection Replace GPS Abnormal activity of the gas pressure sensor Manual Automatic Communication failure Contact to Navien tech dept Abnormal the Water E039 Flow Senor 1 Check the water flow sensor Outdoor 1 Check the Thermistor E040 Thermistor short 2 Replace the Thermistor E048 Abnormal LPG Gas 1 Check the LPG Gas Manual Pres sure 2 Fill the LPG Gas 55 Navien America Inc 2010 CH series service Manual Version 1 0 5 3 01Error Error conditions and check items NGC In order to prevent boiling of the heat exchanger if the heating water temperature 01E of 208 F 98 C or higher is sensed continuously for 15 seconds the thermostat displays the error message 01E manually cancelled and the boiler becomes Lock Out performing post purge The system stops the post purge process if the heating or returned water temperature becomes 167 F 75 C or lower Boiling 1 Check the circulation pump operating status 2 Check the 3 way valve operating statu
12. D rU que rm pm m i a FEIEREN l ee A a N W PPP Sr 1 S a lt Electrode gap 3 4mm gt lt Electrode gap error gt When no spark is made from the electrode at ignition V Remove the electrode and check if there is a crack on the insulator V Adjust the gap if there is a discharge of electricity from the metallic part of the combustion room No spark from V Add the insulating packing to the insulator of the electrode electrode V Check the input power to the ignition transformer AC 120V V If there is no trouble in the input power to the ignition trans Ignition former replace the ignition transformer failure V Replace the PCB if there is a trouble in the power supply to the ig nition transformer V Check the insulator boots on spark wires for cracks holes Ignition transformer 1 Check the primary secondary power supply to the main gas control valve V Check with a tester if the input power is DC 100V 2 Replace the PCB if power is not supplied 3 If power supply is normal check if the coil is open 4 Check if the solenoid valve works properly V Feel or hear a click Main gas valve 65 ONavien America Inc 2010 CH series service Manual Version 1 0 lt Main gas valve gt lt Check DC voltage gt 1 Check the location of the flame rod if there is any deformation or debris and repair or replace the part 2 Check the sheath of the flame rod wire
13. F 37 60 C Temperature Range R C Space 98 185 F 37 85 C Heating Flame Rod Overheat Cut off Device Ignition Operation Detector Safety Devices Water Temperature High Limit Switch Exhaust Temperature High Limit Switch Decese Plumb Easy Valve Set Outdoor Sensor Pressure Relief Valve Condensate Neutralizer Communication Cable ONavien America Inc 2010 18 CH series service Manual Version 1 0 3 2 Dimensions A Connection Diameter hah ES H Exhaust Air Intake epum Connection DR A Connection Hot Water Outlet 3 4 Gas Inlet 3 4 Auto Feeder 1 2 ONavien America Inc 2010 CH series service Manual Version 1 0 4 System Details 4 1 Schematic and Water Flow Diagram 4 1 1 Space Heating Mode Primary Heat Exchanger Secondary Heat Exchanger Circulation Pump Motorized 3 Way Valve Auto Feeder Valve Include Check v v Flow Sensor DHW Heat Exchanger Main Gas Valve E TT LI O LJ LJ LJ O M Heating Return Gas Supply Space Heating Supply Water Supplement The space heating water is controlled by the thermostat boiler control provided This control enables the user to either set the desired room temperature or set the heating water temperature In some cases this thermostat may not be suitable for multi system applications The installing contractor will make this determination and install suitable alternative controls 20 ONavien America Inc 2010 CH serie
14. Other setting setting error or max setting trouble Defective If the trouble continues despite the checking of above items PCB replace the PCB 58 ONavien America Inc 2010 CH series service Manual Version 1 0 5 3 02Error Error conditions and check items Error Description If the water pressure sensor senses low water level as the heating pipe pressure is low the system stops operation of the boiler and refills water automatically As water is filled to the normal water pressure the system automatically cancels error operates the pump for 15 seconds and returns the system to the previous state When water is filled for the first time after the power is connected the system 02E operates the pump in the hot water mode Low water level lt Conditions for low water level detection gt The system refills water if water level of 7 3 PSI or lower is detected for over 4 seconds The system stops filling water at the water level 12 PSI the value is depending on the set ting Filling is stopped forcefully if the water level is 7 4 PSI or higher after 3 minutes from starting of water refilling 1 Defective pressure sensor 2 Defective pressure display 1 Water is not refilled V Check if the cold water valve is closed or frozen V Check if the auto feeder valve works normally 2 Water overflows through condensed water hose V Check the left drain valve of the main heat exchanger V Check if water
15. Primary Heat Exchanger S H Supply Adaptor BH2507551A APS Venturi BH2501413A S H Return Adaptor BH2507551A DHW Cold Water Inlet Adaptor BH2507396A Burner Ignition Transformer Air Pressure Sensor PABNCWA8KDBN 002 BH1201045A NASS9EX00009 Auto Feeder Valve BH0904011A Exhaust Duct BH2544007D Main Gas Valve BH0901018A 17 Exhaust Pipe CH series service Manual BH2505401B Version 1 0 3 Technical Data 3 1 General Specifications H 240 Item CH 180 C CH 240 ASME Heat Capacity Rate Min 17 000 Btu h Min 20 000 Btu h Min 20 000 Btu h Input Max 150 000 Btu h Max 175 000 Btu h Max 199 000 Btu h 35 F Rise 8 3 Gal m 10 0 Gal m 11 Gal m Heat Capacity Input 45 F Rise 6 5 Gal m 7 7 Gal m 8 6 Gal m 77 F Rise 3 8 Gal m 4 6 Gal m 5 1 Gal m Dimensions W17 x H27 x D12 Weight 74 lbs 84 lbs Installation Type Indoor Outdoor Wall Hung Venting Type Forced Draft Direct Vent Ignition Electronic Ignition Domestic Water Pressure 45150 Psi min max AO Heating Water Pressure 7 0 30 Psi min max Efficiency AFUE 91 Gas Supply Win Max 6 0 10 5 W C Pressure Manifold Gas Min NG 0 4 W C NG 0 4 W C NG 0 6 W C Pressure Max NG 3 7 W C NG 3 0 W C NG 4 0 W C Minimum Flow Rate 0 5 GPM Heating DHW Coedo Gives Supply Return Inlet Outlet Auto feeder Gas Supply 1 NPT 3 4 NPT 1 2 NPT 3 4 NPT DHW 98 140
16. boiler operates with the pre heating function It is impossible to switch the hot water mode from the room controller but the pre heat lamp flickers only Lukewarm water is acquired Replace the flow sensor An error in internal circulation of the boiler due to debris caused by aging of pipe Check if the space heating strainer is clogged Check if the DHW heat exchanger is clogged with debris To check if the DHW heat exchanger is clogged touch both sides of the DHW heat exchanger and check if there is substantial difference of temperature The temperature of hot water at the tap is low while the tempera ture is high at the hot water outlet The hot water pipe is installed such that hot water is mixed with cold water Cold water and hot water are mixed due to improper installation of the tap No hot water from the faucet Check the pipe ONavien America Inc 2010 The boiler cold water valve is closed Check if the cold water filter is clogged with debris Check if the cold water hot water pipes are frozen during the winter 109 CH series service Manual Version 1 0 Check method Error type Cause Check method Remark Check if the space heating strainer is clogged with debris Check the cause of debris if the space heating strainer is clogged Aluminum distributor oxidized steel etc The space heating strainer is clogged No space heating while the boiler runs Location
17. error message error 1 Check if the gas is supplied normally 2 Check if the GPS hose is bent or torn 3 Check the GPS parts 4 Check the PCB parts During gas valve ON is the output voltage of GPS normal d Replace GPS GPS Gas PressureSensor Check the voltage between black and white wire of CN 7 0 2 0 6VDC d Replace GPS Yes During gas valve OFF is the output voltage of GPS normal Check the voltage between black and white wire of CN 7 1 AVDC Yes Check connector 103 ONavien America Inc 2010 CH series service Manual Version 1 0 Check method Error type Cause Check method Remark No gas is Check if the valve is closed or if there is a problem in supplied the gas meter GPS hose Check if the GPS hose is bent or torn Defective GPS part Check the output voltage Check the harness Gas Pressure Sensor Black Red Input DC 4 5 5 5V CN7 Black W hite Output while in Standby DC 0 2 0 6V IDC 0 3 4 5V Black White Output while Operating DC 1 4V DC 0 3 4 5V Other Defective Check the output If the trouble continues despite the trouble PCB checking of above items re place the PCB 104 ONavien America Inc 2010 CH series service Manual Version 1 0 5 25 36Error Error occurrence conditions and check items Error Description 36E Communi cation error If no response is made during communicatio
18. into the boiler After reassembling check for gas and water leakage Then test ignition Make sure that there is no gas leakage in connections by testing with soap bubble solution Bubbles indicate a gas leak that must be corrected Check the performance and operation after servicing To remove and replace any parts on this unit you will need a magnetic tip screwdriver that is at least 8 10 inches long A flashlight and magnetic tip reach are also handy Navien recommends the use of a parts tray or bowl to hold small parts and screws All of the hardware is essential to the proper operation of the unit upon re assembly NOTICE When disassembling and reassembling the combination boiler refer to the components diagram amp parts list 118 Navien America Inc 2010 CH series service Manual Version 1 0 8 2 Components Replacement Instructions 8 2 1 PCB 1 Turn off the gas supply 7 Loosen the PCB upper 1 screw from 2 Turn off the 120V power supply PCB bracket 3 Turn off the water supply 4 Remove the four screws securing the front panel Remove front panel 5 Remove the all connecting housing into the PCB Figure 3 8 Pull out the PCB en 9 Attach the new PCB tighten screws 6 Loosen the PCB 2 screw from 10 Connect the all connecting housing bottom PCB bracket into the PCB 11 Install front panel using 4 four Se 1 V screws uds EB x 7 12 Turn on water supply power sd Al eX
19. is a problem in power supply check the output voltage of the PCB and take the action separately for wiring error and defective PCB respectively If the power supply is normal replace the remote controller 111 CH series service Manual Version 1 0 6 Inspection 6 1 Preparing the Boiler for Inspection Precautions on security before working Inspection items and entire procedures Tools required when inspection Volt Ohm Amp meter with test probes Digital manometer or U tube type manometer with 14 inch water column W C scale a hose and two 1 8 inch taps Assorted screw drivers Leak solution or leak detector Teflon tape 112 ONavien America Inc 2010 CH series service Manual Version 1 0 6 2 Measuring Gas Pressure Setting 6 2 1 How to Check Inlet Gas Pressure All Safety messages will refer to potential hazards Precisely follow the instructions to avoid the risk of injury The Navien water heater cannot operate properly without sufficient inlet gas pressure and volume Below are instructions on how to check the inlet gas pressure THIS SECTION IS ONLY TO BE DONE BY A LICENSED PROFESSIONAL Procedure to measure the inlet gas pressure 1 Shut off the manual gas valve on the supply gas line 2 Open a hot faucet The unit should turn on and the gas in the gas pipe line should purge Leave the faucet on to keep the unit running until the unit shuts down due to lack of gas supply The
20. located in 2 places n P Gas Type C H 1 80 Model Name BEI Navien Code LU RI IN UPCC ode 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 e Read and understand the safety information before operating or servicing this Navien Boiler About Notation in the Manual Indication of Refer To The p mark is used to indicate the chapter or section you should refer to its format is as indicated below P 3 1 General Specification of 3 1 8 ONavien America Inc 2010 CH series service Manual Version 1 0 Abbreviation and definition Abbreviation Description of changes CH General name of CH 180 CH 210 and CH 240 and CH 240 ASME NG Natural Gas LP Liquid Gas AP Air Pressure APS Air Pressure Sensor DHW Domestic Hot Water FM Fan Motor GARC Gas Air Ratio Control GPM Gallon per Minute GPS Gas Pressure Sensor GV Gas Valve Main and Solenoid MG M Main Gas Valve Modulating Valve S Solenoid Gas Valve G R PC Printed Circuit Board E Electromagnetic Interface V V V B MI L HT High Temperature Limiter 9 ONavien America Inc 2010 CH series service Manual Version 1 0 1 Safety Considerations 1 1 Safety Definitions All Safety me
21. of space heat ing strainer gt L HEATI DATE Combus tion ON OFF IS repeated lt Check the space heating strainer gt if the Defective circulation pump Defective circulation in distribu tor and pipe Defective thermistor heating circula tion flow is low Low circulation due to defective circulation pump impeller Low circulation pump RPM Replace the pump Check if the distributor room valve is open Low heating circulation flow as the distributor or aged pipe is clogged If only 1 valve of the distributor is open heating is delayed or is not done due to low circulation of space heating water If heating is not done evenly adjust the distributor valves to make the circulation even Heating is not done due to defective supply thermistor or return thermistor If the temperature is sensed higher than the actual temperature replace the thermistor No combus tion of boiler Detect DHW flow Continuous heating is not provided due to 5 min waiting function when there is small leakage from DHW pipe Water flow is detected according to the change of direct water pressure V Continuous heating may not be provided due to o min waiting function when water flow is detected at the site where a direct water pressurizing pump is used VY Remove the water flow sensor connector operate the heating function and check if temperature changes Normal if the water flow value is 00 when the boiler
22. should be switched ON if the corresponding unit is the first or the last unit of cascade connection 28 Navien America Inc 2010 CH series service Manual Version 1 0 4 4 Wiring Diagram O External Transformer Ground Main Power Code Pump Remote Controller Ges 0 0 W BK Y W Modulating mn a i Gas Valve O e O OJO CN 14 CN12 CN9 or O O 8 2 O O Dip S W 7 15 BBBHBE BBBBBBBB Ol 15 ods ena CN18 9 Dip S W 2 S H Return Thermostat O BK BK CS 8 O i 16 E S H Supply Thermostat 1 FE B w A Min LH wax Exhaust High Limit S W O W 15 Modulating G C odulating Gas W 16 Valve Adjusting Thermal Fuse CN13 E High Limit S W ED R Ol Water Pressure Sensor BK O BK CH CN22 Outdoor Thermostat CWS B re O teste GD B O CN6 CN1 BK O O C Service use Q Flow Sensor W IO 0 R O SW4 SW3 CN5 R re E ON GPS Gas Pressure Sensor W CH E U AC24V Switch H BK Q 6 OFF OC CN7 CN25 CNA CN23 CN10 CN24 DM aes Air Pressure Sensor D L ao oo ooo J rj B B OW Y BK Color
23. sole discretion The Labor Allowance will be paid based on Navien s Schedule of Labor Allowances TRANSFERABILITY 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 WARRANTY EXCLUSIONS This warranty does not cover the following conditions L 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 L 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 L 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
24. the flue including dent 2 Check if rainwater is collected due to downward installation of air supply pipe supply exhau Exhaust gas st flue flows in through the supply pipe If the exhaust gas glows in through the air supply pipe imperfect combustion may cause 10E due to noise and instable APS and RPM V Check the installation of flue and if the standard flue is used Air pressure sensor controller Detection error ONavien America Inc 2010 If the same trouble continues after reviewing of the above items 1 replace the air pressure sensor or 2 replace the PCB 80 CH series service Manual Version 1 0 5 12 11Error Error conditions and Symptoms Analysis Error Description 11E Upon receiving a signal from the water pressure sensor the system displays the Water following error pressure 1 E11 High water level sensor V igh water level error if the water level of 56 6PSI or higher continues 3 seconds error Error is cancelled if water level is 43 5PSI or lower 1 E11 Room controller E11 main Check V Check the pressure increase conditions high water pressure of 3 9 bar or higher items 2 E11 Room controller SEE SEE on the main display Sensor Error V Check if the water pressure sensor is frozen during the winter Replace the defective water pressure sensor No Replace the water pressure sensor Is the water pressure sensor normal Yes W
25. trouble continues despite the checking of above items replace the PCB 70 CH series service Manual Version 1 0 5 6 05Error Error conditions and Symptoms Analysis Error Description 05E Disconnetion Check the supply temperature sensor If a problem open 14 F or lower is of supply detected for 3 seconds the system displays the error message 05E on the indoor temperature thermostat sensor 1 Check if the supply temperature sensor is open and if the connector is connected properly 2 Replace the defective heating temperature sensor 3 Replace the PCB normal Yes Check connector Check method Possible Causes Is the hot water thermistor No Replace hot water thermistor Resistance between two red white wires of CN 13 is from 0 8 to 20k ohm at normal condition Caution Before measuring resistance of the thermistor remove the connector form the PCB Check method Defective temperature sensor Sensor connector error Check if the supply temperature sensor is open and if the connector is connected properly Temperature sen sor Other Defective trouble PCB ONavien America Inc 2010 1 Measure the resistance of the temperature sensor 2 If the resistance is abnormal replace the temperature sensor If the trouble continues despite the checking of above items replace the PCB 71 CH series service Manual Versio
26. 0 ASME Water heated in the primary secondary heat exchanger is circulated to the Function plate heat exchanger where the heat of heating water and tap water are exchanged so that hot water is available 1 Water leakage through a crack Failure Event 5 improper heat transfer can cause the cold water in heat exchanger Effects 1 The unit will stop operating once detecting water leakage 2 DHW does not come out Error Code E001 E016 E030 The plate heat exchanger filters out impurities in space heating pipes to prevent heating problems caused by impurities Leak in plate heat exchanger will cause pressure in space heating side to increase to tap water pressure level Diagnostic Color Number of wires N A Heat Flow Y Hot Water Cold Water Heat Fow map L lt cola water ON Return NL Hot Water 49 ONavien America Inc 2010 CH series service Manual Version 1 0 4 6 18 Circulation Pump Navien Part No NAPUSGLPCT10 Check Point e 1 Pump operates for internal or external hot water circulation Function 2 Internal circulation will avoid hot and cold water sandwich and external hot water circulation delivers hot water to fixtures quickly resulting in water conservation Failure Event 1 Unable to detect or measure water flow rate Only circulation mode 1 The water heater freezing Effects 2 Abnormal of i
27. 1 3 SYMBOLS USED IN THE INSTRUCTIONS 10 14 SAFETY PRECAUTIONS t 11 2 PRODUCT INFORMATION iiien 16 54 PRODUCTINFORMATI N eee 16 22 LAYOUT AND KEY COMPONENTS tt 17 a TECHNICAL DATA NO OO UTEM 18 3 1 GENERAL SPECIFICATIONS ee 18 55 DIMENSIONS ssusipteeeinstaeplorele beto ee ee ee 19 A SYSTEM DETAILS ee 20 4 1 SCHEMATIC AND WATER FLOW DIAGRAM serere 20 a1 opace Reang EE 20 445 Di is 21 45 OPERATION TELOW CHART EE 22 As DIP GWITCH Ser TING gree 26 AA WIRING DIAGEAN neuter tet eee 29 A5 ELECTRICAL DIAGNOSTIC Te Tu EE 30 AG KEV COMPONENTS DESCRIPTION ee 33 453 e SE 33 402 TheonnalPF sB EENEG 34 RE AR E EEN 35 4 6 A High Limit Switch or Exhaust Limit Swilch nnn 36 45 5 EEN ee Ee 37 E ee 38 1 ONavien America Inc 2010 CH series service Manual Version 1 0 4 6 7 Flame FRO ASS Y ttti 39 4 6 8 Ignition Transformer eene 40 2 5 9 APO EE 41 40 10 MANO EE 42 45 11 Man G s Val setts ected aes ni en teh gc eee clea ee eed eed ir 43 46 12 GPS cereieeeenes i aaa 44 a 45 4 6 14 Flow Sensor s 46 EE 47 4 6 16 Secondary Heat Exchanger iiti 48 4 6 17 DHW Heat Exchanger 7 7 7 7 7 7 9 9 9 9 nene 49 2615 Caon ees 50 4 6 19 3 Way Valve 7 7 7 7 7 7 7 7 7 7 7 7 nene 51 42520 Wael DICSSUIC Sensor ee teet ene EM nce 52 PES MP Tz ci erase et ae eee eee ieee 53 5 TROUBLESHOOTING 7 7 7 7 9 9 eee 54 DA ERROR CODE
28. 142 CH series service Manual Version 1 0 Description Navien Part No BH2202022A BH2202025A 210 240 Tube 550L BH2202023A 180 BH2202024A BH2203001A 210 240 Tube Screw D4 x 8L BH2202036A 180 BH2202041A BH2421008A BH1705007A 210 240 Screw D4 x 6L BH1612004A Bolt D4 x 10L STS Screw D4 x 14L BH1611006A BH1701031A Screw D4 x 14L BH1708006A Bolt M4 x 12L STS Screw D4 x 25L Fan Motor Damper BH1603007A BH1701030A BH2505403C O Ring BH2421003A Screw D4 x 4L Navien America Inc 2010 BH1710001A 143 CH series service Manual Version 1 0 9 3 Water Way Disassemble 144 Version 1 0 CH series service Manual Navien America Inc 2010 NO Description Navien Part No Remark 15 High Limit Switch BH1401022A 16 High Limit Switch Bracket BH2501541A WPS Packing BH2406054A H E Bracket R BH2501704B H E Bracket L BH2501703B Inlet Water Filter BH1303013A Heat Exchanger Ass y A do BBM20341008 210 240 41 Exhaust Duct BH2544007D 42 Exhaust Duct Packing BH2406050A 46 Primary H E Inlet Adapter BH2501558A 47 Primary H E Outlet Adapter BH2507602A H E Outlet Pipe BH2507556A 180 BH2507555A 210 240 H E Middle Pipe BH2507531A Auto Feeder Pipe BH2507552A SPH Inlet Pipe 1 BH2507367B SPH Inlet Pipe 2 BH2507366B 54 H E Inlet Pipe MU ds BH2507553A 210 240
29. 500 RPM ORANGE RED WHITE sie YELLOW BLACK 23 4 87mm 38 ONavien America Inc 2010 CH series service Manual Version 1 0 4 6 7 Flame Rod Ass y PH1603058D NG Navien Part No Check Point N A PH1603059D LP 1 To igniting gas by repeatedly discharging the high voltage spark to the main burner until igniting gas Function 1 Unable to ignite during the ignition process 2 Makes attempts to ignite at all times Failure Event 1 The unit cannot ignite during the ignition process and E003 or E004 Effects error codes will display 2 No effects on the unit however the durability of the igniter wears down Error Code E003 E004 Diagnostic 1 Visual inspection Connection and or breakage of wires Color Number of wires Bracket Flame rod Insulator wire Ceramic Igniter Flame rod 39 ONavien America Inc 2010 CH series service Manual Version 1 0 4 6 8 Ignition Transformer Navien Part No BH1201041D Check Point o 1 To igniting gas by repeatedly discharging the high voltage spark to the Function main burner until igniting gas 1 Unable to ignite during the ignition process Failure Event 5 Makes attempts to ignite at all times 1 The unit cannot ignite during the ignition process and E003 or E004 Effects error
30. 56 Auto Feeder Packing BH2406063A 57 Auto Feeder Cover BH0712006A 59 S H Return Adapter BH2507551A 60 DHW Inlet Adapter BH2507560C DHW Flow Sensor AASSOEXFSOO2B DHW Outlet Pipe Ass y BH2507590A DHW Outlet Adapter BH2507558A 65 DHW Heat Exchanger eee PAS40KHE_003 210 240 66 S H Strainer BH1301020C 67 S H Return Pipe BH2507550A 69 S H Pipe 2 BH2507372B 71 Siphon BH2501442C 72 Siphon Hose BH2204047A 145 Navien America Inc 2010 CH series service Manual Version 1 0 Description Water Pressure Sensor Navien Part No BH2507535A Secondary H E Inlet Adapter BH2501602A BH2501603A 210 240 Circulation Pump NAPU9GLPCT10 Pump Drain Plug Pump Bracket BH2505314A BH2501447A Pump Packing BH2406039A Fastener C O Ring 17 5x2 7t BH2507018B BH2422026A O Ring P16 Back up Ring Packing Ring 3 4 BH2422017A BH2507308A BH2406025A Pump Fastener Clip A BH2507445A BH2507013A Clip C BH2507345A Screw D4 x 16L O Ring 24 8x 17 8t BH1708004A BH2423058A Fastener B BH2507016A Fastener D 100 Screw D4 x 8L BH2507402B BH1705007A 101 Bolt M4 x 16L 104 Bolt D4 x 10L STS 106 Bolt M4 x 12L BH1603009A BH1611006A BH1612007A 110 Screw D4 x 14L BH1701003A 114 Bolt M4 x 8L BH1603015A 119 H E Packing BH2406048A 120 O Ring P16 121 Fastener A ONavien America Inc 2010 BH2422017A BH2507400B 14
31. 6 CH series service Manual Version 1 0 10 Inspection and maintenance Schedule 10 1 Annual Servicing For reasons of safety and economy it is recommended that the boiler is serviced annually Servicing must be performed by a qualified service agency or gas supplier Services performed once a year are shown below Inspection Visual inspection for general signs of corrosion Checking and adjusting the gas air ratio Checking Flue Gas Carrying Out a Water Leak Test in Operation Carrying out a gas leak test in operation Checking Hot Water Temperature and Flow Checking Noise Checking venting systems Checking the remote controller e Maintenance Draining the boiler and cleaning the inlet water filter Cleaning the Return Filter Cleaning the intake air filter Flushing the heat exchanger Replacement of parts 147 ONavien America Inc 2010 CH series service Manual Version 1 0 10 2 Inspection Report Inspection Items References Visual Inspection for General Signs of Corrosion YES NO Checking and Adjusting the Gas Air Ratio YES NO Carrying Out a Water Leak Test in Operation YES NO Carrying Out a Gas Leak Test in Operation YES NO Checking Hot Water Temperature and Flow YES NO BENI Checking Noise YES NO Checking Venting Systems YES NO Checking the Remote Controller YES NO 148 ONavien America Inc 2010 CH series service Manual Version
32. Code B Blue 0 Orange a des I a 7 AC zr R Red BK E 2 A H A H T S T S adde ae dS Y Yellow A Cooling Heating Heating Cooling BK Black i pa Q pa BR Brown AC 19V GR Y Green Yel low Dini MGV SV lord Main Gas Valve Solenoid ain Fan Motor Valve 1 SV2 Solenoid Valve 2 Flame rod Spark Electrode Main Gas Valve Solenoid Valve Connecting Wiring Color e a BR BR W Version 1 0 CH series service Manual Navien America Inc 2010 4 5 Electrical Diagnostic Points Navien America Inc 2010 AR wei EE co Te AE Ir RE eti 30 CH series service Manual sis remi ci fe we zd Y k L EE L albe bed d Version 1 0 4 5 Electrical Diagnostic Points Point nction Wire Color Normal Value Check Currency changes as controlling Modulating BLACK BLACK m gas volume after operating the Valve DC 2 10V A gas valve Outlet T RED RED DC 0 5V Voltage change according to A temperature iiet Tern DC 0 5V Voltage change according to p WHITE WHITE temperature Return Voltage change according to Temp BLUE BLUE DC 0 5V temperature Supply 8 Voltage change according to B Temp BLACK BLACK DC 0 5V temperature Normally input pulse Confirm rms Exhaust HTP WHITE WHITE DC 4 6V voltage as measuring DC meter 8 Normally input pulse Confirm
33. LI S mes e bc ee 54 Bo OMEDDOR 1 meta MU MU DUE 56 5 3 O2ERROR nn 59 5 4 OSERROR 7 7 7 7 M M MMM MM M 61 5 5 OJ4ERROR nn M H M HH 69 5 6 OS ERROR ee 71 5 7 OGD ERROR o nnn netting 72 oT POY Al En 73 5 9 08ERRORH nnn M MQM s n n n en gen Hs 74 5 10 O9ERROR E 75 5 11 10ERROR E 78 5 12 11ERROR BE 81 5 13 12ERROR H E R 82 5 13 13ERROR En 84 5 15 15ERROR M NE UEM IMEEM ME EE MEM UU MEME EE UN MEME MEE MM MEM MEE CE M MEM 86 5 1 6 16ERROR 87 5 17 18ERROR ee are E I E Uc M ICI ciu I c 90 5 1 8 19ERROR A EU 92 5 19 21 ERROR een 94 5 20 22ERROR A O He ee 96 5 21 27ERROR hou UE UL EU uU MEINE MEE EE EU MEMINI MEI UE 98 2 ONavien America Inc 2010 CH series service Manual Version 1 0 5 22 28ERROR 100 5 23 3OERROR o 102 5 24 35ERROR nnn 103 5 25 36ERROR nnn nnn 105 5 26 39ERROR in 106 5 27 40ERROR enn enn 107 5 28 TROUBLESHOOTING GUIDE BY SYMPTOM veee 108 DUC CEN LI NEN 108 5057 EE 109 EE E 110 6 INSPECTION n T s H n
34. PCB If the same phenomenon replace the thermistor If the trouble continues despite the checking of above items replace the PCB Check short circuit of the cold water inlet thermistor gt ONavien America Inc 2010 97 CH series service Manual Version 1 0 5 21 2 Error Error occurrence conditions and check items Error Description 27E Abnormal air pressure sensor voltage of 1 20V is detected before pre purge the system displays the error Sensor message 27E on the remote controller error If an error open 0 1 0 1V or lower short circuit 4 5 0 2V or higher in the air pressure sensor is detected continuously for 3 seconds or if the air pressure uring fan motor stop is the Check Check the assembly of the connector of the air pressure sensor items Check the voltage of the air pressure sensor output voltage of ES Beacons APS normal Check the voltage between black and white wire of CN 6 0 2 0 6VDC Yes O gt Replace APS During fan motor operation is the output voltage of APS normal N Yes Check the voltage between black and white wire of CN 6 1 4VDC Y Replace PCB 98 ONavien America Inc 2010 CH series service Manual Version 1 0 Check method Error type Cause Check method Remark Check connector assembly and contact of the air pressure sensor Disconnector Abnormal sensor 1 Black White y Opera
35. Service Manual NaVICN Condensing Combination Water Heater Heating Boiler enuen aons INGIAPIN MODEL CH 180 CH 210 CH 240 CH 240 ASME NaVICN Condensing Combination Water Heater Heating Boiler Ver 1 00 A 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 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 e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e f you cannot reach your gas supplier call the fire department Jejog BuneeH egen Jaye uoneuiquio H2 Installation and service must be performed by a qualified installer service agency or the gas supplier oNaVIewN Navien America Inc 20G Irvine CA 9261 C oodyear Irvine CA 92618 1 Edition July 2010 TEL 949 420 0420 FAX 949 420 0430 WWW naviennamerica com No 20A GT 002 NaVI eN Contents REVISIONS M H M M ni Hn e 5 NAVIEN WARRANTY a 6 HANDLING OF THIS MANUAL ccc munem eae 8 ABBREVIATION AND DEFINITION eee er 9 i SAFETY CONSIDERATIONS ege 10 id SAFETY DEFNITIONS EE 10 1 2 LIST OF SAFETY SYMBOLS IN THIS MANUAL ii 10
36. Visual inspection check the Auto feeder valve connection wire 2 Voltage check Check range of voltage shown below Blue Blue ON AC 97 138 V OFF 0 V Automatic Water Fill Valve Navien America Inc 2010 53 CH series service Manual Version 1 0 5 Troubleshooting 5 1 Error Code List Reason Self diagnostic Action Reset 1 Clean the inlet water filter 2 Check the heat exchanger flush with a cleaning solution E002 Low water pressure 1 Wait until water supplement is terminated Check if the main gas supply valve is open Check the igniter for spark Water is boiling inside Manual the heat exchanger Ignition failure Manual Check if the main gas supply valve is open False flame detection Check the igniter for spark Automatic Heating supply outlet Ensure ground wire is connected Thermistor open Check the igniter for spark Automatic Check the thermistor Check for loose connection Replace the thermistor Heating supply outlet Thermistor short CHEN Check the thermistor Check for loose connection Replace the thermistor Hot water outlet Thermistor open Auomang Check the thermistor Look for short or water in connection Replace the thermistor Hot water outlet Thermistor short ATOAN Check and clean the air filter Check and clean the fan motor Check tower on board for loose connection Abnormal fan motor activi
37. age between two wires of CN17 Same as supply voltage 97 138 VAC Yes Is the igniter electrode clean Is the igniter electrode damaged e d Clean or replace igniter electrode Remove the burner cover plate and check the igniter electrode Yes Replace igniter assembly Scenario2 Is the flame detection device normally operating Yes Try to restart Navien America Inc 2010 Clean or replace the flame rod No Check whether ground circuit is properly installed Is the flame current detected Check the current of CN 19 7 20UA Check the voltage between two wires of CN 19 Yes 10 20VDC Replace PCB 62 CH series service Manual Version 1 0 Scenario3 Does the main gas valve have proper voltage Is gas valve normally operating No Check connector Check the voltage between two brown wires 1 2 of CN 15 83 120 VDC Yes Does the main gas valve have proper resistance No Replace gas valve assembly Check the resistance between two brown wires 1 2 of CN 15 0 8 2 4k ohm ve Check connector Check the voltage between two wires of CN 14 2 10VDC Yes Does the modulating gas valve have proper voltage Yes Is the tube which is connected with modulating gas valve properly installed d Check tube Yes C
38. al Version 1 0 9 2 Burner Disassemble ee ALAN d S MAN NK A i ET d te 141 Version 1 0 CH series service Manual ONavien America Inc 2010 NO Description Navien Part No Remark 17 Fan Motor NAFA9GSFBOO2 18 Flame rod ass y poe iis PH1603059D Propane 18 1 Eiamerod BH2501679A NG BH2501680A Propane 18 2 Flame rod packing A BH2405054A 18 3 Flame rod packing B BH2405051A 18 4 Flame rod bracket BH2501681A 20 Air Pressure Sensor NASS9EX00009 PABNCN30KDBN_004 180 NG PABCR180ABN_003 180 Propane SR PABNCWA8KDBN 003 210 240 NG PABCR210 240ABN 003 210 240 Propane 24 Burner Bracket L BH2501444C PABCR180AMF 001 180 NG l PABNR NP180AMF_001 180 Propane e eae PABCC210AMF 001 210 240 NG PABCC210AMF 002 210 240 Propane Solenoid valve PH0905028A APS venturi BH2501413A APS venturi packing BH2405031A BH1419012A 180 29 Thermal fuse BH1419013A 210 240 30 Ignition transformer BH1201045A BH2501605A 180 31 Fan motor bracket oe BH2501604A 210 240 BH2546020A 180NG BH2546024A 180 Propane 23 Gas Pipe BH2546021A 210 240 NG BH2546025A 210 240 Propane BH2507663A 180NG BH2507733A 180 Propane 34 GPS venturi BH2507664A 210 240 NG BH2507732A 210 240 Propane 34 1 GPS venturi tube BH2203002A Gas pressure sensor GPS bracket NASS9EXGPSO1 BH2507346A Main gas valve BHO901018A Gas inlet adapter ONavien America Inc 2010 BH2507714A
39. art of the Gas Air Pressure Gas Air Pressure Difference Type 3 Stage Min Burn 3 Stage Max Burn Natural Gas 0 86 0 04 W C 2 68 0 08 W C Natural Gas 0 63 0 04 W C 1 61 0 08 W C cu up A zur Natural Gas 0 63 0 04 W C 2 13 0 08 W C gas valve Air Pressure Gas Pressure Proportional valve Minimum Modulating PCB Board AUI aet s SaL Maximum Modulating 115 ONavien America Inc 2010 CH series service Manual Version 1 0 7 Maintenance Describe precautions before maintenance and show tools required when maintenance 7 1 Draining the Combination Water Heater Boiler Procedure to drain the unit figure below You will need to prepare a bucket to collect some of the water to be drained 1 Turn off the power to the unit 2 Close the gas valve 3 Close the water supply valve on the space heating return to the unit If there is no valve turn off the water supply valve at the water meter 4 Open the pump drain plug on the pump and allow the water to drain 5 Open the pump drain plug at hot outlet side open the drain valve inside the unit open the drain valve at the pump and remove the filter from the space heating return side 6 When the water is completely drained return the pump drain plug and the inlet filter and close the pump drain plug inside the unit 116 ONavien America Inc 2010 CH series
40. ater pressure sensor Connector Open or Short ve Check Connector No Regulating pressure in unit drain Check method Possible Check method Causes Check the pressure increase conditions high water pressure of 3 9 bar or higher V Defective expansion tank V Excessive forceful water refilling V Check if the safety valve is stuck High water E11 E11 pressure Defective water 1 Check if the water pressure sensor is frozen during the winter E11 SEE pressure sensor 2 Replace the defective or opened water pressure sensor 81 Navien America Inc 2010 CH series service Manual Version 1 0 5 13 12Error Error conditions and Symptoms Analysis Error Description If the system detects loss of flame during combustion the system stops supplying fuel repeats restart counts the loss of flame incidents and if the incident occurs 20 times in series displays 12E manually cancelled on the indoor thermostat 12E Flame loss Measure with a meter the gas supply pressure NG 6 10 5 W C LP 98 15 5 W C Check the Gas meter Capacity Check the Gas Pipe Diameter 3 4 or wider Check the PCB DIP S W capacity setting 3 stage MIN differential gas pressure adjustment error Defective air pressure sensor Check if the nozzle is clogged Defective multi stage valve Defective proportional valve in the main gas valve 0 Check if the PCB works properly
41. avien America Inc 2010 CH series service Manual Version 1 0 Supply Thermistor gt 208 F NO Outlet Thermistor lt 14 F NO Outlet Thermistor gt 248 F NO Control Board Abnormal NO High Limit Switch 1 Open NO Inlet Thermistor lt 14 F NO Inlet Thermistor gt 248 F NO High Limit Switch 2 Open NO Supply Thermistor lt 14 F NO Supply Thermistor gt 248 F NO Return Thermistor lt 14 F NO Return Thermistor gt 248 F Lock out 001E Lock out 007E Lock out 008E Lock out 015E Lock out 030E Lock out 016E Lock out 021E Lock out 022E Lock out 005E Lock out 006E Lock out 018E Lock out 019E ONavien America Inc 2010 25 CH series service Manual Lock out MGV OFF SGV1 OFF SGV2 OFF Watch dog OFF Igniter OFF GV Igniter Power OFF Main Power Reset YES Power ON Version 1 0 4 3 Dip Switch Settings There are two sets of DIP switches one set has 6 switches and the other has 8 switches Set of Dip Switch 1 6 Switches DIP S W Description No Function Operation Select 1 1 Operation Mode Select Operation Select 2 1 2 3 Gas Type Select Model Select 1 5 Factory Setting 6 Model Select 2 1 amp
42. c 027E YES A Lock out Igniter OFF Dusk H Lock out 010E FM Control APS normal YES 22 ONavien America Inc 2010 CH series service Manual Version 1 0 4 2 Operation Flow Chart YES Lock out A ER 035E YES MGV ON Igniter ON MV ON Flame ON during 10sec Ignition Failure straight 3 times Lock out ilis 003E Igniter ON for 1sec after Flame ON NO Igniter ON Igniter OFF v Burner Operation Faucet Close YES Flow Sensor lt 0 48 GPM NO NO Lock out P NO Flame OFF straight 20 times during burner operation Lock out YES 012E S S Lock out 010E NO Lock out YES TERIS NO Lock out GPS normal YES 035E NO GARC Excess Air Pressure YE 23 ONavien America Inc 2010 CH series service Manual Version 1 0 HC medium range YES YES 7 SV2 OFF y SV2 ON Igniter OFF YES Igniter OFF YES Z O 015E Lock out Burner Operation O No F YES DHW 3 WAY Valve On CH 3 WAY Valve Off Heat Demand YES CH 3 WAY Valve Off CH 3 WAY Valve Off Post Purge Fan amp Pump ON for 3 min Pump On 24 N
43. codes will display 2 No effects on the unit however the durability of the igniter wears down Error Code E003 E004 1 Visual inspection Connection and or breakage of wires Diagnostic 2 Voltage check Check range of voltage shown below Color Blue Blue On AC 97 138 V Number of wires Off 0 V 2 48 63mm Input Voltage Output Voltage Output Current 115V 60Hz 19KV 2KV 10mAt2mA 40 ONavien America Inc 2010 CH series service Manual Version 1 0 4 6 9 APS Navien Part No NASS9EX00009 Check Point e Function 1 Sensing the air pressure for air velocity following gas supply 2 APS device automatically controls the quantity of air supply operate with GPS Failure Event Effects 1 The combustion noise occurs 2 Imperfect and or lifting flame occurs 1 The boiler is not operating 2 Excess carbon monoxide emissions greater than 400ppm Error Code E009 E010 E027 Diagnostic Color Number of wires ONavien America Inc 2010 1 Visual inspection Connection and or breakage of wires 2 Voltage check Check range of voltage shown below 1 Red black DC 5V 2 White black DC 0 3 4 5 V Diaphragm a Air Pressure a Air Pressure L 3 66 93 0mm 41 CH series service Manual Version 1 0
44. component may not operate within the unit In most cases of PCB Effects Board failure the whole unit does not operate at all Error Code E015 Diaanostic 1 Visual inspection Connection and or breakage of wires and or burn s marks on the PCB Board Color Number of wires 33 ONavien America Inc 2010 CH series service Manual Version 1 0 4 6 3 Transformer Navien Part No BH1419012A BH14190013A Check Point Function 1 To supply power to the main PCB board 2 Every electrical component of the unit is designed to only work with a 120VAC power supply therefore the unit comes equipped with this transformer Failure Event Effects 1 There is no power coming from the transformer 2 The voltage from the power supply cannot be converted to 120 VAC 1 To supply power to the main PCB board 2 Every electrical component of the unit is designed to only work with a 120VAC power supply therefore the unit comes equipped with this transformer Error Code Diagnostic Color Number of wires ONavien America Inc 2010 N A 1 Visual inspection Connection and or breakage of wires 2 Voltage check Check range of voltage shown below Black Black 185 C 56 11 Emm 210 240 0 26 6 6mm Iewen Ae 34 CH series service Manual Version 1 0 4 6 3 Transformer 1 To supply power to the main PCB board Function 2 Every electrical component of t
45. d 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 e Improper adjustment alteration service or maintenance can cause property damage personal injury or death o prevent scalding always check the temperature of the hot water after servic ing e 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 INSTALLATION REQUIRMENT e 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 14 ONavien America Inc 2010 CH series service Manual Versi
46. deposit on the burner fin surface and or unstable flame conditions during operation Diagnostic Color Number of wires UOS SJ NA AA 1459493 AAKKELAK E SOA X Y au OH SS Y yu ASA E a RR AS AAA Fuel Gas Supply Combustion Air Supply 45 ONavien America Inc 2010 CH series service Manual Version 1 0 4 6 14 DHW Flow Sensor 1 To sensing water flow and GPM Gallons per minute for steady hot Function water temperature 1 Unable to detect or measure any water flow rate Failure Event 2 Water leakage from the water flow sensor 1 Ignition sequence does not start Effects 2 Stop operating once detecting water leakage Error Code 1 Visual inspection Connection and or breakage of wires Diagnostic 2 Voltage check Check range of voltage shown below 3 Open drain and verify that impellor spins freely Color 1 Red black DC 5V Number of wires 2 White black DC 0 3 4 5 V Water Outlet 46 ONavien America Inc 2010 CH series service Manual Version 1 0 4 6 15 Primary Heat Exchanger Navien Part No N A Check Point N A 1 Main part for heat transfer from the burner Function 2 There is additional path of water pipes on the heat exchanger surface as well as inside the combustion chamber and it minimizes the heat loss 1 Water and or exhaust gas leakage through a crack 2 Improper heat transfer can cause the water in heat exchanger to boil Fail
47. direction and secure 2 When installed the condensation trap connecting hose it should be installed from the secondary heat exchanger drain port first and then to trap 12 13 14 Ge 16 Version 1 0 8 2 12 Flow Sensor 1 Turn off the gas supply Turn off the 120V power supply 3 Turn off the water supply Drain all water from the appliance 4 Remove the four screws securing the front panel Remove front panel 5 Pull out the PCB refer to 8 2 1 PCB 6 Remove the fastener C and the heating water inlet pipe Ve N Figure 32 7 Loosen the domestic cold water inlet adaptor 2 screws Figure 33 131 ONavien America Inc 2010 CH series service Manual 8 Remove the fastener A and water flow sensor from bottom base domestic hot water exchanger Figure 35 9 Replace the Oring in service parts included remove parts 10 Reseat the water flow sensor from the domestic cold water inlet adap tor and domestic hot water exchanger 11 Replace the fastener A 12 Tighten the cold water inlet adaptor 2 Screw 13 Replace the heating water inlet pipe and fastener C 14 Replace the PCB refer to 8 2 1 PCB 15 Install front panel using 4 four screws Version 1 0 1 1 6 Turn on water supply power supply and gas supply 7 Open a hot water tap and ensure there are no leaks at the boiler NOTE 1 When it drained might be water temp
48. e appliance 4 Remove the four screws securing the front panel Remove front panel 5 Disconnect the water pressure sensor wire housing from the PCB Figure 42 134 6 Loosen the water pressure sensor 7 Pull out the water pressure sensor Figure 43 8 Replace with new water pressure sensor 9 Connect the water pressure sensor wire housing into the PCB 10 Install front panel using 4 four screws 11 Turn on water supply power supply and gas supply 12 Open a hot water tap and ensure there are no leaks at the boiler NOTE 1 Always use right part O ring and right size and place to pipe Navien America Inc 2010 CH series service Manual Version 1 0 8 2 16 Space Heating Strainer Filter Cleaning or Strainer Replace 1 Turn off the gas supply 2 Turn off the 120V power supply 3 Turn off the water supply Drain all water include heating water from the appliance 4 Removing the stainless from the space heating strainer body Figure 45 6 Replace with new strainer filter 7 Turn on water supply power supply and gas supply 8 Open a hot water tap and ensure 9 Pull out the space heating strainer there are no leaks at the boiler Figure 44 NOTE 1 Always use right part O ring and right size and place to pipe 135 ONavien America Inc 2010 CH series service Manual Version 1 0 8 2 17 Auto Feeder Valve 1 Turn off the gas supply 2 Turn off the 120V power su
49. e between black and red wire of CN 8 120 180VDC Yes Is there any pulse output from the fan motor No Replace fan assembly Check the voltage between black and white wire of CN 8 2 8VDC Yes Y Replace PCB 76 ONavien America Inc 2010 CH series service Manual Version 1 0 Check method Possible Cause Blower No blower action error action Blower Defective RPM error rotator Navien America Inc 2010 Check method 1 Check the power supply to the blower V Black Red approx DC 127 184V 2 Replace the PCB if power is not supplied normally 3 Replace the PCB if power is supplied normally 4 If the trouble continues despite the checking of above items replace the blower Check the blower operation voltage 1 If RPM is significantly low while the blower works and the power supply is normal replace the blower 2 If RPM is low or there is a sensor circuit error replace the blower 3 If the trouble continues despite the checking of above items replace the PCB 7 CH series service Manual Version 1 0 5 11 10Error Error conditions and Symptoms Analysis Description The system senses the air volume and the RPM signal and displays 10E on the indoor thermo stat in the following cases During prepurge If the air volume sensor voltage fails to reach the standard voltage ignition 10E voltage while the FAN RPM signal is sensed the syst
50. e following cases 1 If the RPM signal is 400 or lower at pre purge the system repeats pre purge 10 times If the RPM remains 400 or lower the system determines RPM error and the boiler switches into Lock Out gas valve and ignition transformer locked However the air volume sen sor should be normal If the RPM signal of 400 or lower is detected for 3 seconds during combustion the system stops combustion and the boiler switches into Lock Out However the air volume sensor should be normal If the pre purge RPM signal of 400 or lower is detected and the voltage of the air vol ume sensor is lower than the standard voltage ignition voltage the system determines RPM error and the boiler switches into Lock Out ONavien America Inc 2010 Check if the blower works normally If it does not work normally check the power supply to the blower Black Red approx DC 180V 2 Replace the PCB if there is a problem in power supply 3 If the trouble continues despite the checking of above items replace the blower 4 If RPM is significantly low while the blower works and the power supply is normal replace the blower 5 If the blower connector is wet due to any reason including leakage take the corrective action 6 Check for loose connection of white tower on PCB 75 CH series service Manual Version 1 0 Does the fan motor have nominal operation voltage d Check power and connector Check the voltag
51. e igniter 10 Attach the new ignition electrode and tighten screws 11 Connect the trans cable and flame rod cable into the ignition electrode and flame rod 12 Attach the fan to be replaced refer to 8 2 4 Fan Motor 13 Install front panel using 4 four 7 Remove the flame rod cable SCrews 14 Turn on water supply power supply and gas supply Figure 10 NOTE Always use factory seal packing between the electrode and burner assembly Figure 11 8 Loosen the 2 ignition electrode screws 123 ONavien America Inc 2010 CH series service Manual Version 1 0 8 2 6 Ignition Transformer Turn off the gas supply Turn off the 120V power supply Turn off the water supply Remove the four screws securing the front panel Remove front panel 5 Pull out the fan assembly refer to 8 2 4 Fan Motor 6 Remove the Ignition Transformer Cable refer to 8 2 6 Ignition Trans former 7 Remove the igniter connecting hous Figure 14 ing into the PCB AOON 9 Pull out the Ignition Transformer 10 Attach the new ignition transformer tighten screws 11 Connect the Ignition transformer cable into the ignition electrode 12 Connect the igniter connecting housing into the PCB 13 Install front panel using 4 four screws 14 Turn on water supply power supply and gas supply Figure 13 8 Loosen the two igniter screws NOTE 1 Check up whether fixing exactly done 2 Check up the c
52. e occurs check the gas supply system pressure Adjust gas pressure at Min 4 Check the differen tial gas pressure Check if there is any Ignition failure occurs if there is debris in the nozzle debris in the Y Disassemble the manifold and check the nozzle Stage 1 nozzle 67 ONavien America Inc 2010 CH series service Manual Version 1 0 1 Remove 4 screws and remove the ignition transformer and the venture 4 Remove 5 Use multi stage valve remove the valve 6 Disassemble the manifold 7 Check the nozzles Defective Defective air air supply supply Check if rainwater is collected due to downward air intake Other troubl Defective If the trouble continues despite the checking of above items er troube PCB replace the PCB 68 Navien America Inc 2010 CH series service Manual Version 1 0 5 5 04Error Error conditions and check items Error Description 04E False flame detection Check items Is the flame detected during no burner 1 Pre ignition false flame If a flame signal is detected before combustion standby prepurge preignition a false flame error 04E automatically cancelled is displayed on the indoor thermostat and the system performs continuous postpurge 2 Post purge false flame If a flame signal is detected when the system performs post purge as fuel supply is stopped a false flame error 04E automatically cancelled is display
53. eck AWS valve or connector Y es 3 Voltage between pin1 and pin3 of CN21 is 120VAC No Replace main PCB 100 ONavien America Inc 2010 CH series service Manual Version 1 0 Check method Error type Cause Check method Defect Unit Leakage 1 Check if there is leakage inside the boiler 2 Check if there is leakage in the heat exchanger V Select the trial mode DIP S W 2 2 ON and if drain continues through the condensed water hose the system determines the heat exchanger defective Leakage lt Check if condensed water is gener ated in the trial mode gt No water refilling delay feeder valve Defective the auto 1 If water is not refilled check the filter in auto feeder valve V Check if water is not refilled or delayed due to clogging of the auto feeder valve V Drain heating water through the drain cork on the bottom of the pump and try refilling again 2 Check the operating voltage 120V V If power is supplied normally replace the auto feeder valve V If power is not supplied replace the PCB Water pressure sense error Water pressure sense error Suspension lt Check the filter and the valve terminal gt Abnormal the Water pressure sensor Abnormal display Suspension of cold water supply or the cold water frozen Navien America Inc 2010 PCB If the trouble continues despite the checking of above items
54. ective PCB Boiling noise How to check boiling noise Raise the water temperature to 158 F Beep 70 C and check the noise Exhaust gas flown into the boiler through the air intake makes combustion noise Check the distance between intake and exhaust Low gas Check the distance between exhaust pipes if two or more units pressure are installed whirring Check if there is any obstacle near the exhaust pipe Noise occurs due to flame lifting when gas pressure is low Noise Check the gas supply pressure during Low gas supply due to incorrect setting differential pressure combustion Disassemble the nozzle and check if the hole is narrowed due to debris Noise from Set DIP S W 1 2 to ON 3 stage MIN and check the flame Compare flame of Burner at combustion section of stages 1 2 and 3 Check the nozzle if there is a comparatively unbalanced burner section Noise due to defective air pressure sensor Replace the air pressure sensor burner stage switch Noise during Noise due to torn air pressure hose combustion Noise may be intermittent depending on the size of the damage 108 ONavien America Inc 2010 CH series service Manual Version 1 0 5 28 2 Hot water Error type Cause Check method Cold water from hot water pipe Low hot water temperature Improper plumbing Hot water pipe and direct water pipe are inverted Abnormal flow sensor Abnormal 3 way valve Abnormal rotatin
55. ed on the indoor thermostat and the system performs continuous postpurge 1 Check if gas leaks due to defective sealing of the main gas valve 2 Check if electricity is discharged from the electrode 3 Check if gas is supplied at higher pressure than the standard gas pressure 4 Defective PCB No gt Clean or replace flame rod operation Check the current of CN 19 7 200A Check the voltage between two wires of CN 19 10 20VDC Yes Y Replace PCB Navien America Inc 2010 69 CH series service Manual Version 1 0 Check method Error type Flame before after combustion Leakage from main gas valve Cause Check method Replace the main gas valve if flame occurs before combustion or if there is remaining flame after combustion is stopped Thudding noise caused by minimum flow Discharge of electric ity from electrode Spark discharges from electrode to flame rod at ignition V Replace or correct location of flame rod Gas block Gas may leak as the gas block is pushed by the gas supply over the standard pressure V Check the supply pressure NG 6 10 5 inch WC V Ifthe gas pressure is too high transfer the problem to the gas oriffice and replace the main gas valve V If gas leaks close the main gas valve and repair the unit before using the system Other trouble Defective PCB Navien America Inc 2010 If the
56. em retries pre purge If Air presure the air volume sensor voltage fails to reach the standard voltage after 5 pre Sensor purge processes the system determines the wind pressure error or the wind error pressure hose error and the boiler switches into Lock Out During combustion of boiler If the current RPM is higher than the standard RPM by 1 000 or higher the system deter mines the wind pressure error excessive wind pressure and stops the combustion process The boiler switches into Safety Shutdown and runs the fan continuously If the current RPM becomes within the standard RPM 500 the system cancels the error and returns to the standby mode Check the air pressure hose visual inspection on tear and hole and water remained in the hose after installation Check if the venture burner hole is clogged Check if the condensed water hose or the drain is clogged Check the flue and exhaust environment Inflow of exhaust gas generates noise Check if the air supply exhaust flue is clogged rainwater collected due to dent or downward installation Check the flue environment inflow of exhaust gas Defective air pressure sensor or PCB 78 ONavien America Inc 2010 CH series service Manual Version 1 0 Replace APS Does APS have nominal Check Connector operation voltage No gt Check the voltage between black and red wire of CN 6 4 5 5 5VDC APS Air Pr
57. ems 2 Check if the outdoor temperature sensor is defective 3 Defective PCB 107 Navien America Inc 2010 CH series service Manual Version 1 0 9 28 Troubleshooting guide by symptom 5 28 1 Noise Error type Cause Check method Defective of Incorrect level setting or fixing error installation V Check the fixing state and reinstall the unit Vibration caused due to defective the fan motor balance Vibration V Touch the fan If vibration is significant replace the fan motor Fan motor l noise V If intermittent noise occurs during operation check the fan vibration olor Hose y If vibration noise occurs during operation of the product and stops when the case lid is removed check he fan motor Regular noise occurs Noise from Noise of motor running continuously due to defective 3 way valve operation of MICRO s w 3 way valve Motor rotation noise Replace the 3 way valve Regular noise Incorrect setting of Gas differential pressure Gas and air Adjust differential pressure with the pressure adjusting screw on differential the main gas valve pressure DIP S W 1 2 ON Stage 3 MIN 1741 mmH O 210 240 model Noise at Tor If noise occurs at standard value adjust setting above below the standard Excessive gas supply due to defective proportional valve on the main gas valve Explosive Replace the main gas valve ignition Gas supply error due to defective air pressure sensor ignition Pop Beep Def
58. er Defective If the trouble continues despite the checking of above trouble PCB items replace the PCB I H Check if the thermistor is open 91 Navien America Inc 2010 CH series service Manual Version 1 0 5 18 19Error Error occurrence conditions and check items Error Description 19E Sieg f If an error short circuit 248 F or higher in the space heating return thermistor is SEN detected continuously for 3 seconds the system displays the 19E error message Space The boiler maintains the Safety Shutdown status and if the heating temperature is heating sensed normally stops postpurge and returns to the standby mode return thermistor Check 1 Check if the thermistor connector is wet due to any reason including leakage eu 2 Replace the defected thermistor items 3 Replace the PCB Is the Return thermistor normal No Replace Return thermistor Resistance between two black wires of CN 13 is from 0 8 to 20KO at normal condition Yes Caution Before measuring resistance of the thermistor remove the connector form the PCB Check connector 92 Navien America Inc 2010 CH series service Manual Version 1 0 Check method Error type Cause Check method Remark Defective Defective thermistor thermistor connector Thermistor If the same phenomenon replace the thermistor Check if the thermistor connector or the harness terminal is wet due to a
59. er is clogged with debris strainer is 2 Check the cause of debris if the strainer is clogged clogged Aluminum distributor oxidized steel etc f E Thudding noise caused by minimum flow lt Heating strainer gt lt Checking strainer gt The main heat or the 1 Separate inlet outlet pipe of the main heat exchanger and blow hot water air with mouth to check if the pipe is clogged heat 2 If the 01 Error occurs when hot water is used only check if the exchanger hot water heat exchanger is clogged is clogged 57 ONavien America Inc 2010 CH series service Manual Version 1 0 lt Check if the hot water heat exchanger is clogged gt Check heating inlet outlet valve and distributor room valve vale closed V At least one valve of the distributor must be always open The system recognizes the heating water temperature higher than it actually is due to a defective sensor Thudding Defective Y Check the heating outlet temperature displayed noise heat ing V Check if there is a significant difference between the tempera caused by Outlet tem ture displayed and the one actually sensed minimum perature Y Remove the heating outlet temperature sensor connector only flow sensor connect a good temperature sensor and determine if the temperature sensor is defective Refer to the resistance measuring criteria and the method of measurement Capacity Sudden increase of temperature due to PCB DIP S W model
60. erature still high 2 Use right size of O ring 3 When it drained careful to wet other electrical components 8 2 13 Circulation Pump 1 SE 3 ONavien America Inc 2010 Turn off the gas supply Turn off the 120V power supply Turn off the water supply Drain all water from the appliance Remove the four screws securing the front panel Remove front panel Pull out the PCB refer to 8 2 1 PCB Remove the drain plug on the pump Open the drain plug on the pump Loosen the screw from bottom base x e Figure 36 132 9 Remove the stainless clip 11 12 13 14 15 16 CH series service Manual Figure 37 10 Remove the stainless nut from the circulation pump Figure 38 Pull out the circulation pump Pull out the circulation pump Replace the O ring amp packing in service parts Replace with new circulation pump Replace the stainless clip Reseat the non threaded end of circulation pump into the stainless fitting At this time be watchful the black gasket ring packing Version 1 0 17 Tighten the 4 screw from bottom 8 Remove the stainless clip fastener L 1 base 18 Close the drain plug 19 Replace the PCB refer to 8 2 1 PCB 20 Install front panel using 4 four Screws 21 Turn on water supply power supply and gas supply 22 Check the operating circulation pump and ensure there are no leaks at the space heating piping
61. ersion 1 0 5 15 15Error Error conditions and Symptoms Analysis Error Description 15E If an error occurs in the internal circuit of the PCB e g resistance transistor or PCB error relay fault the system displays 15E PCB error message 1 Defective PCB 2 Check with a tester if the PCB is in the rated voltage AC 97V 138V 3 Disconnect the grounding wire and check the PCB Replace the main d PCB Check items After press reset button to normal Yes Normal state Check method Possible Check method Causes Defective PCB Replace the PCB if there is an error in the PCB internal circuit Check with a tester if the PCB is in the rated voltage 15E Power supply Check with a tester if the voltage at the receptacle is PCB error error 97V 138V Power supply Power supply grounding noise causes malfunction grounding VY Disconnect ground by applying a tape on the grounding noise terminal in the receptacle and check if the PCB works normally 86 Navien America Inc 2010 CH series service Manual Version 1 0 5 16 16Error Error occurrence conditions and check items Error Description 16E If the high limit switch cutoff on the heat exchanger is sensed to be 197 F or higher High Limit continuously for 1 second at combustion stop of the boiler the system displays the Switch 16E manually cancelled heat exchanger high limit switch cut off
62. esource Confirm the FUSE Confirm the circuit breaker ON DC83 120V Confirm voltage as the Main Gas SEKR OFF OV Valve operating Gas Valve YELLOW YELLOW ON DC83 120V Confirm voltage as the Gas OFF OV So lenoid Valve 1 operating M ON DC83 120V Confirm voltage as the Gas RED RED OFF 0V So lenoid Valve 2 operating E S ON AC97 138V Confirm voltage as the 3 Way ii wane PAE BERGE OFF OV Valve operating N ON AC97 138V Confirm voltage as the circulation FS YELLOW WHITE OFF 0V pump operating ON AC 97 138V Confirm voltage as Auto Water 9 A PAE BENE OFF 0V Feeder valve operating P E GREEN Protect Earth Same to the case earth Protect Earth P M th easure the currency as Flame Rod BLACK 0 20uA sensing flame pros RED RED AC 123 177V Confirm output voltage bes WHITE BLACK AC 97 138V Confirm output voltage AC 24V R Out put AC 24V Confirm output voltage A H Externally Externally If AC 24V is connected externally AC 24V input On Off Else dry contact input On Off If AC 24V is connected externally AC 24V output On Off Extern Power Navien America Inc 2010 ON AC 97 138V OFF 0V 32 CH series service Manual Confirm voltage as operating Version 1 0 4 6 Key Components Description 4 6 1 PCB Navien Part No NACR1G 32301 Check Point Function 1 To control each component and performance unit Failure Event 1 Malfunctioning PCB Board 1 A
63. essure Sensor No Replace APS Check the voltage between black and white wire of CN 6 0 3 4 0VDC Is there any output voltage from APS No Remove all the restrictions in airflow SADETE ANY TESTIGONG around unit and check the vent pipe airflow Yes y Replace tube Check vent and connector Check method Possible Check method Causes 1 The air pressure hose is clogged V Check if the hose is clogged with water remained from Air presure Air presure installation hose error sensor venturi 2 Check if the venturi burner hole is clogged with soot or debris error V Blow air with mouth through the air pressure hose clogged 3 Check if the air pressure hose is torn y Increased RPM may cause blowout and noise Y 03E can occur due to the same trouble 79 ONavien America Inc 2010 CH series service Manual Version 1 0 Check if the venturi is clogged gt lt Defective wind pres sure hose gt Condensed water drain error Condensed water drain error Exhaust air is locked out due to condensed water drain error V Check if the condensed water hose or the siphon is frozen V Check if the condensed water hose is folded V Remove bottom of trap and verify it is not plugged Defective blower Air pressure error Replace the blower if the blower RPM is considerably low Deformed or clogged flue Defective air 1 Check the exterior of
64. g flow sensor Disassembly cleaning is possible as a temporary measure The priority should be given to replacement of the part owitching from heating to hot water fails If the hot water temperature does not rise while the boiler is running check the heating outlet pipe Check the power supply to the 3 way valve Blue Black AC120V 120V Replace the PCB if power is not supplied Defective space heating supply thermistor Defective DHW heat exchanger Hot water setting error Current thermistor sensing error If no hot water is acquired while the remote controller is in the hot water mode and displays high hot water temperature it is due to the defective space heating supply thermistor Replace the thermistor The hot water temperature is low while the boiler burns and operates normally Direct water is mixed with hot water due to defective internal shape of hot water inlet outlet of the DHW heat exchanger Replace the DHW heat exchanger Check the hot water temperature setting on the remote controller High water pressure Water pressure is too high for the boiler capacity Install a reducing valve and adjust water pressure with an interme diate valve Refer to the hot water supply capacity on the rating plate EX CH 210 Water Temperature 77 F 4 5GPM Defective flow sensor Circulation error due to foreign sub stance Water mixed with cold water In the speed hot water function the
65. he expansion tank and give the explanation to the customer 28E 60 CH series service Manual Version 1 0 5 4 O3Error Error occurrence conditions and check items Error Description In case of an ignition failure repeat restart 10 times If no flame is detected the system displays the error message 03E manually cancelled on the indoor thermostat Check the gas supply check the gas valve and supply pressure Check the gap of electrode electricity discharge or deformation of flame rod Check the operation of the ignition transformer ignition state input power AC 120V Check the operation of the gas control valve DC 100V coil short circuit solenoid valve 5 Check the flame rod and wiring and grounding Check items 6 Check if the APS hose is broken or clogged 7 Check if the APS works properly 8 Check the PCB DIP S W model setting 9 Adjust differential pressure to MIN between 3 stages with the gas manom eter 17mmH O 1 10 Disassemble the manifold and check the nozzle 11 Check the flue and air supply downward installation rainwater collected 12 If the trouble continues despite the checking of above items replace the PCB 61 ONavien America Inc 2010 CH series service Manual Version 1 0 Scenario1 Is the igniter normally operating Yes Check the gas valve assembly Does the igniter have proper voltage d Replace PCB Check the volt
66. he main gas valve y Turn the adjusting screw under the main gas valve 75 turn and check the combustion Excessive air volume occurs if the air pressure is higher than the standard value V Replace the air pressure sensor The flame is extinguished due to foreign substance in the nozzle y Defective stage 1 nozzle causes accidental fire at ignition V Flame may be blown out if the stage is switched when the nozzles of stages 2 and 3 are in trouble V Disassemble the manifold and clean the nozzle Flame may be blown out if the stage is switched when the multistage valve is defective A defective proportional valve of the main gas valve causes trouble in air supply during combustion Y Low gas pressure causes blowout of flame V Thick flame causes noise and accidental fire Other trouble PCB ONavien America Inc 2010 If the trouble continues despite the checking of above items replace the PCB 83 CH series service Manual Version 1 0 5 13 13Error Error conditions and Symptoms Analysis Error Description The system receives change of pressure from the water pressure sensor If no 13E change of pressure is made for 7 seconds after starting of the pump the system stops restarts the pump 3 times If the pressure is remained unchanged the system determines a trouble of the pump and displays the 13E manually cancelled error Pump error message on the remote controller Check if the pump
67. he unit is designed to only work with a 120VAC power supply therefore the unit comes equipped with this transformer 1 There is no power coming from the transformer 2 The voltage from the power supply cannot be converted to 120 VAC Failure Event 1 The unit does not operate due to lack of power from transformer Effects 2 A failed transformer can cause electrical damage to other electrical components within the unit Error Code N A 1 Visual inspection Connection and or breakage of wires and or signs of Diagnostic electrical damage 2 Voltage check Check range of voltage shown below 1 AC 9 V Yellow Yellow AC 7 11 V Color 2 AC 26 V White White AC 22 33 V Number of wires 9 AC 19 V Blue Blue AC 16 24 V 4 Power trans AC 150 V Red Red AC 123 177 V 5 Power trans AC 120 V White Black AC 97 138 V 15 75 400mm 35 ONavien America Inc 2010 CH series service Manual Version 1 0 4 6 4 High Limit Switch or Exhaust Limit Switch BH1401022A Navien Part No Check Point BH1401027A 1 Overheating preventing switch 2 Due to the high temperature it will automatically trip and automatically reset Function 3 Detects excessively high water temperature more than 197 6 F in heat exchanger BH1401022A 4 Detects excessively high flue gas temperat
68. heck the flame rod Check the burner assembly 63 Navien America Inc 2010 CH series service Manual Version 1 0 Check method Cause Check method mode 1 Check if the gas valve is open 2 Check the gas supply pressure NG 6 10 5 inch WC 3 Check the flexible pipe dia 3 4 inch or larger 4 While the static pressure is normal a large difference of dynamic pressure may cause drop of gas pressure Therefore it is required to check the dynamic pressure vus supply X Static pressure Gas pressure at the stop of the boiler SEH Dynamic pressure Gas pressure at boiler max combustion 5 Excessive force in fastening nuts at installation of gas pipe may move the packing and block the Teflon sealing causing a drop of gas supply pressure 6 Check the gas meter class 425 CFH or higher Combination Heater Boiler 195 CFH Furnace 58 8 CFH Domestic gas range 63 7 CFH e 1 CFH 1 020 Btuh Ignition failure Check gas supply pressure Moved packing narrows the inner diameter Defective electrode gap and shape disables ignition Defective V Appropriate electrode gap approx 3 4mm replace if defective electrode v An ignition failure may occur due to improper gap while gap and discharge seems normal when checked via the flame monitoring shape window Therefore it is required to check the gap after disassembly 64 ONavien America Inc 2010 CH series service Manual Version 1 0 EE
69. ill have temperature fluctua tions in hot water Error Code E007 E008 E021 E022 E032 E033 E041 E042 Diagnostic 1 Visual inspection Connection and or breakage of wires 2 Voltage check Check range of voltage shown below 3 Resistance check of sensor Color Number of wires ONavien America Inc 2010 1 Black Black DC 0 5V 2 Blue Blue DCO 5V 3 Red Red DCO 5V 4 Yellow Yellow DC 0 5V 5 Resistance Open infinite Shorted 0 Nomal 4 121kq at 113 F Wire Color Blue Wire Color Black Wire Color Red Wire Colo Yellow 37 CH series service Manual Version 1 0 4 6 6 Fan motor Navien Part No NAFA9GSFB002 Check Point To provide combustion air into the burner and to exhaust flue gas FREED Fan operated with APS or ideal combustion 1 Fan speed failure the fan RPM are less than or equal to 400 RPM Failure Event 2 The fan assembly screw loosens and or the fan is disassembled 3 Connection terminal assembly defectiveness 1 Unstable combustion condition Effects 2 Unit vibrating and making a noise 3 The boiler is not operating Error Code E009 E010 E027 1 Visual inspection check the fan connection wire and or the fan mounting Diagnostic location 2 Voltage check Check range of voltage shown below 1 Black Red DC 127 184 V Color 2 Black Yellow DC 15 V Number of wires 3 Black Orange DC 0 7 5 V 4 Black White 0 6
70. in next page 4 Re open the gas shut off valve Check to see that there are no gas leaks 5 Set the DIP switches for the 3rd stage minimum operation mode 1 ON 2 ON Open a hot faucet 6 When the Navien boiler is burning at the 3rd stage minimum check the gas air pressure difference reading on the manometer Compare the gas air pressure difference with FACTORY setting chart in bottom page When the gas air pres sure difference is out of standard range adjust the pressure difference by rotat ing the proportional valve refer to the following picture in next page 7 Shut off the hot faucet after checking and adjusting the gas air pressure differ ence 8 Set the DIP switches for the 3rd stage maximum operation mode 1 ON 2 OFF Open a hot faucet that has high flow to ramp the boiler up to its maximum burn 9 When the Navien Boiler is burning at the 3rd stage maximum check the gasair pressure difference reading on the manometer Compare the gasair pressure difference with FACTORY setting chart in bottom page When the gasair pres sure difference is out of standard range adjust the pressure difference by rotat ing the variable resistance on the PCB board Controller 10 Shut off the hot faucet after checking and adjusting the gas air pressure gap Close the gas shut off valve Set the DIP switches for normal mode and replace tubes 114 ONavien America Inc 2010 CH series service Manual Version 1 0 Standard Setting Ch
71. is not operating Warm floor when heating function is not used Defective 3 way valve ONavien America Inc 2010 When hot water flows in the heating line as the 3 way valve is not switched to heating for preheating for hot water or due to defective packing Replace the 3 way valve 110 CH series service Manual Version 1 0 Error type Cause Check method The circuit breaker operates immediately as soon as the power cord is plugged in the receptacle Check the sheath of power cord or if there is short circuit Check the devices in the order of the power trans former and the PCB Circuit Defective operation bly Circuit breaker operates while the boiler is running Remote controller Check the Navien America Inc 2010 If the circuit breaker operates after a repairing work check the wiring of each part Mind the direction when assembling the ignition trans former Be careful that wire is not pressed down when assem bling the main gas valve Check if the wire is fixed and well adjusted on the main side of the heat exchanger If circuit breaker operates during the operation of the boiler check the order of operation and replace the concerned part e g The circuit breaker operates at switchover to burner stage 3 after ignition Replace the gas manifold valve Check the power supply to the remote controller terminal DC 19V or higher If there
72. lace the PCB refer to 8 2 1 PCB 11 Install front panel using 4 four screws 12 Turn on water supply power supply and gas supply 121 Navien America Inc 2010 CH series service Manual Version 1 0 8 2 4 Fan Motor Combustion Air Turn off the gas supply 7 Pull out the fan assembly Turn off the 120V power supply Turn off the water supply Remove the four screws securing the front panel Remove front panel 5 Loosen three fixing screws from the fan assembly ZS Go M Figure 9 8 Attach the fan to be replaced 9 Fix the three screws of the fan 10 Attach the harness housing to the fan assembly 11 Install front panel using 4 four screws Figure 7 12 Turn on water supply power 6 Disconnect the harness housing at supply and gas supply the fan assembly NOTE 1 Don t over tight screws with high torque drill It will damage to fan housing 2 Confirm whether the screws tighten enough or not 3 Confirm whether there are unnec essary noises after reinstalled fan Figure 8 122 ONavien America Inc 2010 CH series service Manual Version 1 0 8 2 5 Flame Rod Turn off the gas supply Turn off the 120V power supply Turn off the water supply Remove the four screws securing the front panel Remove front panel 5 Pull out the fan assembly refer to 8 2 4 Fan Motor 6 Remove the Ignition Transformer Cable AOON Figure 12 9 Pull out th
73. ld assembly 11 Reinstall gas valve wires into the manifold to be replaced 12 Attach the manifold and secured with screws Figure 19 IN WARNING 7 Pull out the gas pipe Failure to correctly assemble the components according to these instructions 126 ONavien America Inc 2010 CH series service Manual Version 1 0 13 Replace the gas pipe Replace the Oring where the assembly attaches to the gas connection Make sure the old Oring removed and discarded b 4 14 Replace the PCB refer to 8 2 1 PCB 15 Install front panel using 4 four screws 16 Turn on water supply power supply and gas supply Figure 22 17 Perform the measuring of gas pres sure setting procedure 18 Check for gas leaks NOTE 1 Always replace with new gasket 2 Wiring should be in right position 3 Always use right part Oring and right size and place to pipe 8 2 9 Main Gas Valve Figure 23 Turn off the gas supply Turn off the 120V power supply Turn off the water supply Figure 21 Remove the four screws securing 8 Remove the wire harness connector the front panel Remove front panel from the 2 solenoid valve and modu 5 Pull out the PCB refer to 8 2 1 lating valve PCB 6 Pull out the gas pipe refer to 8 2 8 Manifold 7 Detach the air pressure feedback tube gas pressure sensor tube ZS Go M i 127 Navien America Inc 2010 CH series service Manual Version 1 0
74. le the gas pressure sensor 2 tube 11 Attach the gas pressure sensor and secured with 2 screws 12 Replace the PCB refer to 8 2 1 PCB Figure 26 13 Install front panel using 4 four 6 Pull out the PCB refer to 8 2 1 SOLE PCB 14 Turn on water supply power 7 Loosen the gas pressure sensor supply and gas supply lowerside 2 screws from base NOTE Always use right type of tube and right place Figure 27 8 Remove the gas pressure sensor 2 tube into the gas pressure sensor 129 Navien America Inc 2010 CH series service Manual Version 1 0 8 2 11 Condensation Trap Turn off the gas supply Turn off the 120V power supply Turn off the water supply Remove the four screws securing the front panel Remove front panel 5 Pull out the PCB refer to 8 2 1 PCB 6 Remove the Pin A Drain Conden sate water from the trap ZS Go M Figure 29 T Loosen the three condensation trap screws Figure 30 130 ONavien America Inc 2010 CH series service Manual 8 Remove the condensation trap con necting hose Figure 31 10 d Pull out the Condensation trap Replace with new condensation trap Connects the condensation trap hose Attach the condensation trap and secured with three screws Replace the PCB refer to 8 2 1 PCB Install front panel using 4 four Screws Turn on water supply power supply and gas supply NOTE 1 Always make sure pin on right
75. leaks due to a defective heat exchanger 3 Check if water leaks from the heating pipe Yes Check in unit Leaking Check items Leaking in unit No No Check the Auto feeder v v Auto feeder valve Open Yes Normal Pressure Check DHW cold water No Pressure Yes Normal state 99 ONavien America Inc 2010 CH series service Manual Version 1 0 Check method Cause Check method mode Cold water dela Es bond Turn on cold water tap and check if the valve works or is frozen frozen Defective 1 Check the auto feeder valve filter if water is not refilled auto feeder 2 Check the power supply AC 120V Valve V Replace the auto feeder valve if power is supplied normally Water is not refilled lt Check if the filter is clogged with debris gt 1 Replace the PCB if power is not supplied lt Auto feeder valve terminal in purple gt Drain valve open Check the drain valve under the left of the main heat exchanger Water flow over through the condensed water hose Defective heat exchanger Frequent 02E Pipe leaks ONavien America Inc 2010 Drain valve Water leaks through the condensed water hose due to a defective heat exchanger Frequent water filling can occur due to leakage of pipe Check the leakage on the pipe connector and distributor Check if the water level becomes lower through t
76. lly 2 Check the power supply to the pump If power supply is normal use a multi tester to V Check if the condenser is defective V Check if there is disconnection of the pump coil 3 If power supply is abnormal replace the PCB Defective high limit switch Check if the contact point of the overheating PCB is defective y Use a tester to see if the resistance is normal OQ or abnormal Defective safety device Abnormal safety device ONavien America Inc 2010 The thermal fuse is disconected Check short circuit of the high limit switch Check with a multi tester if the thermal fuse is disconnected V If the fuse is disconnected replace the part and check the cause of cutoff 88 CH series service Manual Version 1 0 lt Location of thermal fuse gt lt Check if the thermal fuse is disconnected gt Abnormal space This trouble occurs if the heating supply thermistor heating senses the temperature lower than that of the actual supply heating water temperature hermir V Replace the heating supply thermistor Abnormal thermistor 1 Check if the heat exchanger is clogged The heat y Separate supply return pipe of the heat exchanger and blow air with mouth to check if the pipe is clogged V If the 16 Error occurs when hot water is used only check if the DHW heat exchanger is clogged exchanger is clogged No circultion heat The surface temperature
77. message on the remote controller The boiler switches into Lock Out and performs post purge Cut off continuously Check the heating supply return valve Check if the heating strainer is clogged Check the circulation pump operating status Check if the high limit switch is defective Check if the thermal fuse is disconnected Check the heating supply temperature sensor Check if the heat exchanger or the DHW heat exchanger is clogged Check if the heat exchanger is defective COND OBRWNDM Is HTL normally operating Noe Replace HTL HTL High Temperature Limiter Check the resistance between two white wires of CN 13 short circuit 016E Check the resistance between two brown wires of CN 13 short circuit 030E Yes Caution Measuring should be done at least 30 minutes after error Y Replace PCB 87 ONavien America Inc 2010 CH series service Manual Version 1 0 Check method Error type Cause Check method Remark Valve is closed Check if the heating supply return valve is closed Heating The strainer is clogged Check if the heating strainer is clogged with debris y Cleaning debris and analyze the cause and take the preventive action water not circulated Defective circulation pump 1 Check if the pump works normally V If the pump is stuck at trial turn the shaft forcefully with a driver and check if it works norma
78. 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 O Do D D D O O O D O 7 ONavien America Inc 2010 CH series service Manual Version 1 0 Handling of this manual Scope This Service Manual is applicable to Navien Boiler CH Series Product Model discrimination label
79. n 1 0 5 7 06Error Error conditions and Symptoms Analysis Error Description 06E Shortcircuit Check the supply temperature sensor If a problem short circuit 248 F or higher is of heating detected for 3 seconds the system displays the error message 06E on the indoor temperature thermostat sensor 1 Check if the supply temperature sensor connector is wet due to any reason including leakage 2 Replace the defective supply temperature sensor 3 Replace the PCB Yes Y Is the hot water thermistor normal No Replace hot water thermistor Resistance between two red whires of CN 13 is from 0 8 to 20k ohm at normal condition Check connector Caution Before measuring resistance of the thermistor remove the connector from the PCB Check method Possible Causes Check method Defective temperature sensor Sensor connector error Temperture sensor Other Defective trouble PCB ONavien America Inc 2010 Check if the hot water temperature sensor connector or the PCB harness terminal is wet due to any reason including leakage Y Check the current heating temperature on the display 0Q Shortcircuit Measure the temperature sensor resistance if the value is 0Q replace the temperature sensor If the trouble continues despite the checking of above items replace the PCB 72 CH series service Manual Version 1 0 5 8 07Error Error c
80. n America Inc 2010 CH series service Manual Version 1 0 8 2 16 Space Heating Strainer Filter Cleaning or Strainer Replace sss 135 8 2 17 Auto Feeder ViVe tareas 136 8 2 18 Domestic Hot Water Exchange rm e 137 8 2 19 Domestic Hot Water Outlet Collar ii 138 9 COMPONENTS DIAGRAM AND PART LUST n 139 9 1 CASE DISASSEMBLE nn e 139 9 2 BURNER DISASSEMBLE e 141 9 3 WATER WAY DISASSEMBLE e 144 10 INSPECTION AND MAINTENANCE SCHEDULE c 147 10 1 ANNUAL SERVICING vvcssvnnnvvnvnnnnnnittttntnnininietttnennnnniintninnittninninntintinnnitntnntiiiinnnnee 147 10 2 INSPECTION REPORT nennen 148 10 3 MAINTENANCE REPORT 151 4 ONavien America Inc 2010 CH series service Manual Version 1 0 Revisions Version Description of changes Date 1 00 First Issue July 30 10 5 Navien America Inc 2010 CH series service Manual Version 1 0 Navien Warranty GENERAL 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 par
81. n between the mast unit and the slave units the system displays the 36E error message 1 Check if power supply to a boiler unit is off 2 Check if the communication cable is damaged or disconnected 3 Check if the dip switch setting is correct 4 Check if the cascade setting is correct 105 ONavien America Inc 2010 CH series service Manual Version 1 0 5 26 39Error Error occurrence conditions and check items Error Description 39E Flow sensor error As one more units are operating in the cascade system The system displays 39E cleared manually on the remote controller and the PCB and switches into the Lock out mode gas valve and ignition transformer locked 1 Check the supply of cold water Frozen locked valve 2 Defective flow sensor 3 Defective PCB Cancelation cascade system and faucet open YES Water flow out NO Check supply cold water YES Y Check connector Or Replace water flow sensor 106 ONavien America Inc 2010 CH series service Manual Version 1 0 5 27 40Error Error occurrence conditions and check items Error Description 40E Short circuit of While the boiler power is ON the system checks the out temperature and displays outdoor 40E error message if the temperature is 122 F 50 C or higher temperature sensor 1 Check if the outdoor temperature sensor is disconnected and if the connector is Check connected properly it
82. n shut off the hot faucet OPENED CLOSE 3 Remove the screw for the pressure port located on the gas inlet of the boiler 27 A Pressure test port on gas line NK Connect a manometer to the pressure port and reset it to zero Re open the manual gas valve Check to see that there are no gas leaks 6 Open multiple fixtures that have high flow rates bathtub showers kitchen sink to ramp the boiler up to its maximum burn 7 When the Navien boiler is at maximum burn check the inlet gas pressure read ing on the manometer it should read between 6 0 10 5 W C for Natural gas between 8 0 13 5 W C for Liquid Propane 8 The maximum inlet gas pressure must not exceed the value specified by the manufacturer and that the minimum value listed is for the purposes of input adjustment C1 113 Navien America Inc 2010 CH series service Manual Version 1 0 6 2 2 Adjusting the Gas Air Ratio The Navien water heater cannot operate properly without suitable gas air pressure Below are instructions on how to check the gas air pressure THIS SECTION IS ONLY TO BE DONE BY A LICENSED PROFESSIONAL Procedure to Adjusting the Gas Air Ratio 1 Close the gas shut off valve on the supply gas line 2 Remove four screws securing the front panel Remove front panel 3 Connect a manometer of pressure gauge to the gas pressure sensor tube high pressure and the air pressure sensor tube low pressure like following picture
83. nternal circulation caused by preheating failure 3 Abnormal of external circulation caused by preheating failure Error Code E011 E013 1 Visual inspection check the circulation pump connection wire 2 Voltage check Check range of voltage shown below Diagnostic Color 1 Brown White ON AC 97 138 V OFF 0 V Number of wires 2 Brown black ON AC 97 138 V OFF O V OUTLET ES 6 46 164mm L 5 84 148 3mm 50 Navien America Inc 2010 CH series service Manual Version 1 0 4 6 19 3 Way Valve Function Diverts the water from the space heating system to the DHW plate heat exchanger and back based on input from DHW flow sensor and PCB Failure Event 1 No hot water in space heating mode ae 2 No domestic hot water in DHW mode In the case that the temperature of space heating is lower than the set Effects temperature it blocks the water flow path for domestic hot water so that heating water can flow through space heating pipes Error Code E01 E16 1 Visual inspection check the 3 Way Valve connection wire 2 Voltage check Check range of voltage shown below Color Blue Black ON AC 97 138 V OFF 0 V Number of wires gt Confirm voltage as the 3 Way Valve operating Diagnostic E rE A e d cC e ke co CR E e m ce cC a c2 o E ko a E MEL ECH Red
84. ny reason including leakage Other Defective If the trouble continues despite the checking of above trouble PCB items replace the PCB OkQ Defect lt Check short circuit of the space heating return thermistor gt 93 ONavien America Inc 2010 CH series service Manual Version 1 0 5 19 21Error Error occurrence conditions and check items Error Description 21E If an error open 14 F or lower in the cold water inlet thermistor is detected Cold water inlet continuously for 3 seconds the system displays the 21E error message on the thermistor open remote controller The boiler maintains the Safety Shutdown status 1 Check if the thermistor is open and if the connector is connected properly 2 Check the defect of the thermistor 3 Defective PCB Is the Return thermistor normal No Replace Return thermistor Resistance between two blue wires of CN 13 is from 0 8 to 20KO at normal condition Yes Caution Before measuring resistance of the thermistor remove the connector form the PCB Check connector 94 Navien America Inc 2010 CH series service Manual Version 1 0 Check method Error type Cause Check method Defective thermistor Abnormal connector Check if the thermistor is open and if the connector is connected properly sensor Temperture sensor Defective PCB Other trouble Replace the cold water inlet thermistor If
85. oblem short circuit 248 F or outlet higher is detected for 3 seconds the system displays the error message O6E on thermistor the indoor thermostat short 1 Check if the hot water temperature sensor connector is wet due to any reason Check including leakage items 2 Replace the defective hot water temperature sensor 3 Replace the PCB normal Yes Y Is the Supply thermistor No Replace Supply thermistor Resistance between two white wires of CN 13 is from 0 8 to 20k ohm at normal condition Check connector Caution Before measuring resistance of the thermistor remove the connector from the PCB Check method Possible Causes Check method Defective temperature sensor connector Check if the hot water temperature sensor connector or the PCB harness terminal is wet due to any reason including leakage V Check the current heating temperature on the display Temperture sensor Defective PCB ONavien America Inc 2010 Measure the temperature sensor resistance if the value is 0Q replace the temperature sensor If the trouble continues despite the checking of above items replace the PCB 74 CH series service Manual Version 1 0 5 10 O9Error Error conditions and Symptoms Analysis Description 09E Fan Motor RPM error The system checks the RPM signal after the blower starts to run and displays the error message 09E in th
86. oiler 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 gt Vapors FLAMMABLE VAPORS Boiler has a main burner flame Vapors from flammable liquids will which can come on at any time and explode and catch fire causing death may ignite flammable vapors or severe burns Do not use or store flammable products Vapors such as gasoline solvents or adhesives Cannot be seen are heavier than air in the same room or area near the boiler YO a long way on the floor And can be carried from other rooms to the Keep flammable products main burner flame by air currents far away from heater in approved containers tightly closed andout of children s reach 11 ONavien America Inc 2010 CH series service Manual Version 1 0 COMPROMISED VENTING SYSTEM 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 e Be sure to inspect the vent terminat
87. on 1 0 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 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 e Use only the same gas type indicated on the rating plate of the Navien Boiler Rating Plate Using different gas type will cause abnormal ER Fi combustion and boiler malfunction EC uon 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 If the unit does not match requirements do not service please con tact Navien immediately 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 15 ONavien America Inc 2010 CH series service Manual Version 1 0 2 Product Information 2 1 Product Information KD Navien condensing gas boiler is a fully au
88. on moment for ideal combustion with proper air supply 3 The unit is designed to operate properly even when there s low gas pressure supply within certain range of gas pressure 95 96 because GPS makes if possible to check and modulate gas ratio for stable combustion Failure Event 1 Gas leak from the valves 1 Gas leak from the unit 2 No flames Effects 3 No operation of the unit 4 Excess carbon monoxide emissions Error Code E035 E048 only PG model 1 Visual inspection Connection and or breakage of wires Diagnostic 2 Voltage check Check range of voltage shown below Color 1 Red black DC 5V Number of wires 2 White black DC 0 3 4 5 V Gas Pressure Gas Pressure 44 ONavien America Inc 2010 CH series service Manual Version 1 0 4 6 13 Burner PABNCN30KDBN 003 Navien Part No Check Point PABNCWA48KDBN 002 1 Pre Mixed burner 2 Pre Mix system reduces emissions and increase efficiency Function 3 The burner facilitates the air gas mixture necessary to produce the proper heat during the combustion reaction 1 Unable to initialize sustain combustion Failure Event 2 Dust or soot deposit on the burner fin surface 3 Gas leakage from burners 1 An unexpected combustion Effects 2 Unstable flame conditions and or flame loss 3 Ignition failure Error Code E003 E004 E012 Visual inspection Excessive dust
89. onditions and Symptoms Analysis Error Description 07E Hot Water Outlet thermistor open Error Check the hot water temperature sensor If a problem open 14 F or lower is detected for 3 seconds the system displays the error message 07E on the indoor thermostat Check items 1 Check if the hot water temperature sensor is open and if the connector is connected properly 2 Replace the defective hot water temperature sensor 3 Replace the PCB Is the Supply thermistor normal Yes Y No Replace Supply thermistor Resistance between two white wires of CN 13 is from 0 8 to 20k ohm at normal condition Check connector Caution Before measuring resistance of the thermistor remove the connector from the PCB Check meth od Possible Causes Check method Defective temperature sensor connector Check if the heating temperature sensor is open and if the connector is connected properly Temperature sensor Defective PCB ONavien America Inc 2010 1 Measure the resistance of the temperature sensor 2 If the resistance is abnormal replace the temperature sensor If the trouble continues despite the checking of above items replace the PCB 73 CH series service Manual Version 1 0 5 9 08Error Error conditions and Symptoms Analysis Error Description 08E Hot Water Check the hot water temperature sensor If a pr
90. onnecting termi nal 124 ONavien America Inc 2010 CH series service Manual Version 1 0 8 2 7 APS Turn off the gas supply Turn off the 120V power supply Turn off the water supply Remove the four screws securing the front panel Remove front panel 5 Remove the air pressure sensor connecting housing into the PCB ZS Go M Figure 17 8 Pull out the air pressure sensor 9 Attach the new air pressure sensor tighten screws 10 Connect the air pressure sensor tube 11 Connect the air pressure sensor connecting housing into the PCB nue 13 Install front panel using 4 four 6 Remove the air pressure sensor bscrews tube into the burner assembly 14 Turn on water supply power supply and gas supply NOTE As reassemble the air pressure sensor careful with right size and direction Figure 16 T Loosen the air pressure sensor low erside 2 screw from burner assemble 125 ONavien America Inc 2010 CH series service Manual Version 1 0 8 2 8 Manifold Turn off the gas supply 8 Loosen the 2 manifold fixing screws Turn off the 120V power supply Turn off the water supply Remove the four screws securing the front panel Remove front panel 5 Pull out the PCB refer to 8 2 1 PCB 6 Loosen the gas pipe from main gas valve lower and Manifold upper AOON Figure 20 9 Remove the wire harness from the 2 solenoids Figure 21 10 Pull out the manifo
91. or and the air intake pipe annually to ensure safe operation of the boiler e 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 Water temperature over 125 can cause severe burns instantly or death from scalds Households with small children disabled or elderly HOT persons may require 120 F 49 C or lower temperature setting to prevent contact with HOT water To prevent scalding check water temperature after servicing H the proposed boiler outlet temperature is above 125 F 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 O Water Time in EE child can Time Temperature Graph for Hot Water Burns suffer a ful thickness 3rd degree Temperature BUTS gree 70 C 160 F Less than 1 second 60 C 140 F 1 second 55 C 130F 10 seconds 49 C 120 F 10 minutes O A M Go P OO Jo O O 130 Temperature 37 C 100 F Very low scald risk UG WU 55 60 Navien America Inc 2010 CH series service Manual Version 1 0 WHAT TO DO IF YOU SMELL GAS If you do not follow these instructions exactly a fire or explosion may result cau
92. pply 3 Turn off the water supply Drain all water include heating water from the appliance 4 Remove the four screws securing the front panel Remove front panel 5 Pull out the PCB refer to 8 2 1 PCB 6 Pull out the main gas valve refer to 8 2 9 Main Gas Valve 7 Remove the stainless nut from the auto feeder valve body d Y 12 Figure 46 14 8 Loosen the auto feeder valve adap tor 2 screw from bottom base d Mj NOTE 1 Figure 47 136 ONavien America Inc 2010 10 11 11 12 des 13 CH series service Manual 9 Remove the fastener D pull out the auto feeder valve Figure 48 Replace with auto feeder valve Tighten the auto feeder valve adap tor 2 screw from bottom base Reseat the non threaded of auto feeder valve into the stainless fitting Replace the main gas valve Replace the PCB Install front panel using 4 four SCrews Turn on water supply power supply and gas supply Open a hot water tap and ensure there are no leaks at the boiler Always use right part O ring and right size and place to pipe Version 1 0 8 2 18 Domestic Hot Water Exchanger 1 Turn off the gas supply 2 Turn off the 120V power supply 3 Turn off the water supply Drain all water include heating water from the appliance 4 Remove the four screws securing the front panel Remove front panel 5 Pull out the PCB refer to 8 2 1 PCB 6 Pull ou
93. r or Heat ing Black COMMON 51 ONavien America Inc 2010 CH series service Manual Version 1 0 4 6 20 Water pressure Sensor Function They are suitable for analyzing water pressure ratios in heating Failure Event 1 Unable to detect or measure to change water pressure 1 Water filling system does not operate automatically Effects Error Code E02 E11 E13 Diagnostic Color Number of wires ONavien America Inc 2010 1 Visual inspection check the circulation pump connection wire 2 Voltage check Check range of voltage shown below 1 Black Red DC 0 5V Ze E E CERS mme 2 A 4 4 4 A A A 4 Y CZ SS E CHA 2 J lt r gt SS N SS S Legend to cross section drawing Pressure connection Ceramic sensor Amplifier electronics Cover Electrical connection RAST 2 5 52 CH series service Manual Version 1 0 4 6 21 Auto Feeder Valve Navien Part No BH0904011A Check Point o Detect low and high water pressure using the electronic water pressure sensor If water pressure is low Water filling system operates automatically Function Failure Event 1 Water filling system does not operate automatically 2 Water filling system operates continuously Effects Error Code Diagnostic Color Number of wires 1 System is low water pressure 2 If system is high water pressure for automatic filling it is over flow E02 1
94. replace the PCB 101 CH series service Manual Version 1 0 5 23 30Error Error occurrence conditions and check items Error Description If the system senses the signal continuously for 1 second from the exhaust high 30E limit switch installed at the top of the exhaust duct when the boiler burns stopped Exhaust the system displays the 30E automatically cancelled heat exchanger exhaust high high limit limit switch message on the remote controller error The boiler switches into Lock Out and performs post purge continuously Exhaust high limit switch operating temperature 149 F 65 C Check 1 Check if the exhaust high limit switch operates normally items 2 Check if the switch works properly Check method Error Possible type C usos Check method Abnormal contact point of the exhaust high limit switch 149 F 65 C V Remove the switch and check with a multitester the resistance MO defect Abnormal the exhaust high limit switch Abnormal sensor lt Check the exhaust high limit switch gt Other Defective If the trouble continues despite the checking of above items trouble PCB replace the PCB 102 Navien America Inc 2010 CH series service Manual Version 1 0 5 24 35Error Error occurrence conditions and check items Error Description 35E Gas pres The GPS output voltage of 0 1 VDC or 4 5 VDC is detected for 5 seconds the sure sensor system displays the 35E
95. rises due to defective heat exchanger exchanger overheated Y Replace the heat exchanger Defective If the trouble continues despite the checking of above PCB items replace the PCB 89 ONavien America Inc 2010 CH series service Manual Version 1 0 5 17 18Error Error occurrence conditions and check items Error Description 18E Space If an error open 14 F or lower in the space heating return thermistor is detected heating continuously for 3 seconds the system displays the 18E error message The boiler return maintains the Safety Shutdown status and if the heating temperature is sensed thermistor normally stops postpurge and returns to the standby mode open 1 Check if the thermistor is open and if the connector is connected properly 2 Check if the thermistor is defective 3 Defective PCB Is the Return thermistor normal No Replace Return thermistor Resistance between two black wires of CN 13 is from 0 8 to 20KO at normal condition Yes Caution Before measuring resistance of the thermistor remove the connector form the PCB Check connector 90 Navien America Inc 2010 CH series service Manual Version 1 0 Check method Error type Cause Check method Error type Defective Check if the thermistor is open and if the connec Defective thermistor tor is connected properly sensor Thermistor If the same phenomenon replace the thermistor Oth
96. rms H EXHTP BROWN BROWN DC 4 6V voltage as measuring DC meter Outdoor BS Voltage change according to C Temp ORANGE ORANGE DC 0 5V temperature Confirm if voltage flows without RED BLACK DC 5V any relations with the flow sensor WHITE BALCK PULSE Check Pulse RED BLACK WHITE BLACK DC 0 3 4 5V Confirm if voltage flows without any relations with the GPS operating Voltage changes according to the GPS operating BLACK RED YELLOW YELLOW WHITE WHITE DC 0 5V AC 7 11V AC 22 33V Voltage change according to water pressure Confirm output voltage Confirm output voltage RED BLACK DC 5V Confirm if voltage flows without any relations with the APS operating WHITE BLACK DC 0 3 4 5V Voltage changes according to the APS operating BLUE BLUE BLACK RED AC 16 24V DC 127 184V Confirm output voltage Confirm if voltage flows without any relations with the GPS operating BLACK YELLOW DC 15V Confirm if voltage flows without any relations with the GPS operating BLACK ORANGE BLACK WHITE ONavien America Inc 2010 DC 0 7 5V Orpm 6500rpm 31 CH series service Manual Voltage changes as the fan operating Check PULSE Version 1 0 Point nction Wire Color Normal Value Check K Igniter BLUE BLUE GC ter Confirm voltage as ignition operating L Confirm approval of the 1st power Power Input BLUE BLACK AC 97 138V r
97. s 3 Check if the heating strainer is clogged 4 Check if the main heat exchanger or the hot water heat exchanger is Check items clogged 5 Check the heating inlet outlet valve and distributor room valve 6 Check the heating outlet temperature sensor T Check the PCB DIP S W capacity setting 8 Check if the PCB works properly Is the hot water thermistor d Replace hot water thermistor normal Resistance between two red wires of CN 13 is from 0 8 to 20k ohm at normal condition Yes Check unit Caution Before measuring resistance of the Eu thermistor remove the connector from the PCB 56 ONavien America Inc 2010 CH series service Manual Version 1 0 Check method Cause Check method mode Check the circulation pump Defective In the error condition the circulation pump and the fan run circulation continuously pump 1 Check power supply to the circulation pump AC 120V Thudding 2 Replace the PCB if power is not supplied noise caused by minimum flow Touch the heating outlet pipe as the heating function is on and check if the temperature changes If there is no change in temperature check the operation error in Defective the 3 way valve hot water mode 3 way valve V Red Black AC 120V Heating V Blue Black AC 120V Hot water V Defective 3 way valve if power is normally supplied kv Defective PCB if power is not supplied The heating 1 Check if the strain
98. s service Manual Version 1 0 4 1 2 Domestic Hot Water Mode e a p j Primary Heat Exchanger Secondary Heat Exchanger Circulation Pump Motorized 3 Way Valve Auto Feeder Valve Include Check v v Flow Sensor DHW Heat Exchanger Main Gas Valve DHW Hot Water Outlet Gas Supply DHW Cold Water Inlet Water Supplement The domestic hot water DHW is controlled by the user Because the Navien Combination Boiler is a multi purpose design it can provide hot water on demand Navien Combination Boiler will produce hot water only when you use it 21 ONavien America Inc 2010 CH series service Manual 4 2 Operation Flow Chart Faucet Open Stand by Faucet Close NO System Initialization Flow Sensor 220 53 GPM YES o MGV OFF MGV OFF SGV1 OFF SGV1 OFF YES ES GEN NO SGV2 OFF SGV2 OFF y YES NO p A No Air Check Igniter OFF Post Purge 10 sec APS normal NO gt d YES GV Igniter Power DHW Waiting OFF Fan Motor ON for 180 sec Watch dog ON Fan Motor ON AP Check FM start up FM and AP normal Flow Sensor gt 0 53 GPM YES Igniter OFF GV Igniter Power Lock out YES N 4E 2e Flow Sensor gt 0 53 GPM Igniter ON Lock out 015E YES Igniter ON NO Lock out for 1se
99. service Manual Version 1 0 7 2 Cleaning the Intake Air Filter Clean the intake air filter just above the fan and under the air intake pipe in the top left corner of the boiler as the following 1 Remove the screw is located in the circled areas in the figure Intake Air Filter 2 Remove the intake air filter from the bottom of the intake pipe by pulling it out towards the front Intake Air Filter 3 Remove the filter from the plastic assembly 4 Clean it with a toothbrush and water 5 Re fit the screen in to the plastic assembly and fit the filter 6 Frame onto the bottom of the air intake pipe 7 Once the filter is back on the intake pipe reset the fan back to its original posi tion Insert the fan on an angle into the back corner of the case and then move it into its correct position 8 Replace the screws 117 ONavien America Inc 2010 CH series service Manual Version 1 0 8 Replacement of Parts 8 1 Replacement Procedure When performing maintenance and of servicing the combination boiler always turn off the electric power gas and water shut off valve Wait for the boiler to become cool Be careful to avoid injury to your fingers on sharp edges Drain all water from the boiler when removing the water parts Before any disassembly make sure you have a good diagnosis Handle all parts carefully When reassembling prevent any foreign substance i e dust etc from being introduced
100. sing property damage personal injury or loss of life DO NOT OPERATE THE BOILER DO NOT OPERATE ANY FAUCETS omell 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 e Extinguish any open flames and sparks Do not operate light switches or electrical equipment switches e 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 e Immediately call your gas supplier from the outside of the building Follow the gas supplier s instructions e f you cannot reach your gas supplier call the fire department Notify your plumbing heating contractor from the outside of the building 13 ONavien America Inc 2010 CH series service Manual Version 1 0 IMPORTANT SAFETY PREAUTIONS e 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 e DO NOT turn on the boiler unless water and gas supplies are fully opened DO NOT turn on the boiler if col
101. ssages 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 1 2 List of safety symbols in this manual Indicates an imminently hazardous situation which if not avoided A DANGER could result in severe injury or death Indicates a potential hazardous situation which if not avoided WARNING could result in injury or death A Indicates an imminent hazardous situation which if not avoided LEA CAUTION may result in minor or moderate injury CAUTION 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 Warns of a risk of material loss and environmental pollution Indicates additional information that is important but not related to NOTE personal injury or property damage 10 Navien America Inc 2010 CH series service Manual Version 1 0 1 4 Safety Precautions 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 b
102. supply and gas supply E ra ad WE 13 Perform the measuring of gas pres T sure setting procedure ceccceoc sues By aa o UE NOTE 52 2 IS Connecting ports must be right color a and place Figure 2 119 ONavien America Inc 2010 CH series service Manual Version 1 0 8 2 2 Fuse 1 Turn off the gas supply 7 Pull out the fuse 2 Turn off the 120V power supply 8 New fuse into the part C and 3 Turn off the water supply assemble B C 4 Remove the four screws securing 9 Replace the PCB refer to 8 2 1 the front panel Remove front panel PCB 5 Pull out the PCB refer to 8 2 1 10 Fix the PCB screw from PCB PCB bracket 6 Remove the capsule A s B C con 11 Install front panel using 4 four nected to the power cable screws 12 Turn on water supply power supply and gas supply NOTE Before remove press the part B into part C and put together as removing the capsule Figure 5 120 Navien America Inc 2010 CH series service Manual Version 1 0 8 2 3 Transformer Turn off the gas supply Turn off the 120V power supply Turn off the water supply Remove the four screws securing the front panel Remove front panel 5 Pull out the PCB refer to 8 2 1 PCB 6 Loosen the 2 screws from power transformer AUN Figure 6 7 Pull out the power transformer 8 Replace with new power trans former 9 Tighten the 2 screws from power transformer 10 Rep
103. t 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 APPLICABLE WARRANTY PERIODS Period of Coverage Heat Exchanger All other Parts and Components 10 years 5 years Proof of purchase is required to obtain warranty service You can show proof o 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 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 6 ONavien America Inc 2010 CH series service Manual Version 1 0 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
104. t the flow sensor refer to 8 2 12 Flow Sensor 7 Pull out the domestic hot water outlet collar refer to 8 2 19 DHW outlet collar 8 Remove the stainless clip fastener A 9 Remove the stainless clip Figure 49 137 10 Pull out the domestic hot water exchanger 11 12 13 14 To 16 ve 18 Figure 50 Replace the new domestic hot water exchanger Replace the 2 stainless clip Replace the domestic hot water outlet collar Replace the water flow sensor Replace the domestic hot water outlet collar Install front panel using 4 four screws Turn on water supply power supply and gas supply Open a hot water tap and ensure there are no leaks at the boiler Navien America Inc 2010 CH series service Manual Version 1 0 8 2 19 Domestic Hot Water Outlet Collar 1 Turn off the gas supply 9 Pull out the domestic hot water outlet 2 Turn off the 120V power supply collar 3 Turn off the water supply Drain all water from the appliance 4 Remove the four screws securing the front panel Remove front panel 5 Pull out the PCB refer to 8 2 1 PCB 6 Pull out the flow sensor refer to 8 2 12 Flow Sensor 7 Remove the stainless clip fastener A Figure 53 10 Replace with new domestic hot water outlet collar secured it 11 Tighten the domestic hot water outlet adaptor 2 screw from bottom base 12 Replace the stainless clip fastener A
105. the trouble continues despite the checking of above items replace the PCB lt Check short circuit of the cold water inlet thermistor gt Navien America Inc 2010 95 CH series service Manual Error type Version 1 0 5 20 22Error Error occurrence conditions and check items Error Description 22E Shortcircuit If an error short circuit 248 F or higher in the cold water inlet thermistor is of cold detected continuously for 3 seconds the system displays the 22E error message water inlet on the remote controller The boiler maintains the Safety Shutdown status thermistor 1 Check if the cold water inlet thermistor connector is wet due to any reason Check including leakage items 2 Replace the defected cold water inlet thermistor 3 Replace the PCB Is the inlet thermistor normal Caution Before measuring resistance of the thermistor remove the connector form the PCB Check connector No Replace Return thermistor Resistance between two blue wires of CN 13 is from 0 8 to 20KO at normal condition Yes 96 Navien America Inc 2010 CH series service Manual Version 1 0 Check method Error type Cause Check method Remark Defective thermistor Abnormal connector Check if the cold water inlet thermistor connector or the harness terminal is wet due to any reason including leakage thermistor Temperture sensor Other Defective trouble
106. ting voltage 5V Abnormal 2 Black Red V Sensor output V Open 0 1 0 1V or lower V Short circuit 4 5 0 2V or higher V An error occurs if the air pressure sensor voltage of 1 20V is detected before prepurge air pressure sensor Other Defective If the trouble continues despite the checking of above trouble PCB items replace the PCB Check the voltage of the air pressure sensor 99 ONavien America Inc 2010 CH series service Manual Version 1 0 5 22 28Error Error occurrence conditions and check items Description Space heating water pressure of 7 3 psi or lower is maintained for over 5 minutes the system displays 28E regardless of initial power supply 28E If the space heating water pressure of 7 3 psi or lower is detected and becomes Leakage 7 3 psi or lower in 2 hours after water refilling the system displays 28E The error is not displayed until 72 hours is passed after the power is connected initially Check the water pressure sensor Check if the boiler is installed in a low water pressure area Check into pipe and pipe assembly A Does the water leak Yes out of pipe S No Does water supplement After press the reset button terminated within 5min Does water supplement occurred Yes Normal state No AWS Auto Water Supplement During AWS valve operation is the output voltage of AWS valve normal Ch
107. tomatic 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 Model Maximum Heating Input Maximum DHW Input 45 F Rise CH 180 150 000 Btu h 6 5 Gal m CH 210 175 000 Btu h 7 7 Gal m CH 240 199 000 Btu h 8 6 Gal m CH 240 ASME 199 000 Btu h 8 6 Gal m 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 16 ONavien America Inc 2010 CH series service Manual Version 1 0 Navien America Inc 2010 Description Navien Part No Description Navien Part No Intake Air Duct BH2505400B DHW Flow Sensor AASS9EXFS002 Fan Motor NAFA9GSFBO002 Syphon BH2501442C W BH2507535A PS DHW Heat Exchanger PASSOKHE 005 17 S H Strainer BH1301020C 18 Motorized 3 Way Valve AAVC9EX00009 Transformer Gas Pressure Sensor Gas Pipe Secondary Heat Exchanger BH1205011A NASS9EXGPS01 Circulation Pump NAPUSGLPCT10
108. ty Manual 1 Check the vent and fresh air pipe for obstruc tions 2 Check and clean the air filter 3 Check hoses and condensate drain Abnormal air pressure Manual Automatic High water pressure 1 Check the water pressure sensor Check the main gas line valve open Check intake air pipe Flame loss Check ground wire Check power supply Clean flame rod Manual Check the pump Remove air from the pipe Manual Abnormal pump Check power supply Check the Emergency Switch Manual Abnormal control board 54 ONavien America Inc 2010 CH series service Manual Version 1 0 Error Reason Self diagnostic Action Reset Code 1 Turn OFF the system for at least 30 minutes then restart 2 Clean the inlet water filter Manual 3 Check the heat exchanger flush with a cleaning solution Overheating of heat exchanger Check the Thermistor Heating return inlet Check for loose connection Automatic Thermistor open Replace the Thermistor m Check the Thermistor Heating return inlet Check for short or water in connection Automatic Thermistor short Replace the Thermistor Check the Thermistor Check for loose connection Replace the Thermistor Cold water inlet Thermistor open PANIQUE Check the Thermistor Check for short or water in connection Replace the Thermistor Cold water inlet Thermistor short EISES Abnormal activity of the
109. ure more than 149 F in exhaust duct BH1401027A 1 Unable to detect excessively high water temperature if switch fails calle EVERI 2 Unable to detect excessively high flue gas temperature if switch fails 1 Unable to shut down the boiler if the water temperature from the heat Effects exchanger exceeds 197 6 F 92 C 2 Unable to shut down the boiler if the flue gas temperature from the exaust duct exceeds 149 F 65 Error Code E016 E030 1 Visual inspection Connection and or breakage of wires 2 Voltage check Check range of voltage shown below Diagnostic Color 1 Yellow Yellow DC 4 6V Number of wires 2 Red Red DC4 6V 0 84 21 4mm H gt OFF OPEN ON CLOSE 149 39 2 F 104 39 2 F 4044 6544 Automatic Return 179 6 439 2 F 170 6 39 2 F 77 4C 92 40 Automatic Return Flue Gas Water 36 ONavien America Inc 2010 CH series service Manual Version 1 0 4 6 5 Thermistor Navien Part No BH1403081A Black BH1403083A Red BH1403082A Blue Check Point BH1403084A Yellow Function Measure cold mixing H E hot water temperature in the boiler Failure Event Effects Unable to properly measure water temperature within the boiler 1 If the Thermistors fail open or short error code appears before starting operation 2 If resistance values are just off the boiler w
110. ure Event 1 The unit will stop operating once detecting water leakage Effects 2 Exhaust gas leakage 3 Make boiling sound Error Code E001 E016 E030 E037 1 Visual inspection check if there is a crack on the surface of heat Diagnostic exchanger 2 Sound inspection check if there s boiling noise Color Number of wires 47 ONavien America Inc 2010 CH series service Manual Version 1 0 4 6 16 Secondary Heat Exchanger Navien Part No N A Check Point N A 1 Main part for heat transfer from the burner Function 2 There is additional path of water pipes on the heat exchanger surface as well as inside the combustion chamber and it minimizes the heat loss 1 Water and or exhaust gas leakage through a crack 2 Improper heat transfer can cause the water in heat exchanger to boil Failure Event 1 The unit will stop operating once detecting water leakage Effects 2 Exhaust gas leakage 3 Make boiling sound Error Code E001 E016 E030 E037 1 Visual inspection check if there is a crack on the surface of heat Diagnostic exchanger 2 Sound inspection check if there s boiling noise Color Number of wires 48 ONavien America Inc 2010 CH series service Manual Version 1 0 4 6 17 DHW Heat Exchanger PAS40KHE_003 210 240 Navien Part No PAS30KHE_005 180 Check Point PAS4DKHE_004 24
111. works normally If the pressure remains unchanged after the pump is started replace the pressure sensor Pressure sensor error The pump can be stuck from time to time due to debris in the heating water Press the reset button is the pump normal Check connector CN18 or replace pump No Yes 4 Yes During pump operating does water pressure increase higher than 3 0 Psi Repeat pump on and off N times if N 5 d Remove air from pipe Yes Normal state 84 Navien America Inc 2010 CH series service Manual Version 1 0 Check method NM Possible Check method Causes 1 Check if the pump works normally V If the pump is stuck at trial turn the shaft forcefully with a regular screw driver and check if it works normally Thudding 2 Check the power supply to the pump noise Pump V If power supply is normal check the charging discharging of malfunction starting condenser Page V Check if the pump coil is open ou 3 If power supply is abnormal replace the PCB Defective If the pressure remains unchanged while the pump works pressure y replace the pressure sensor and or sensor y replace the PCB The pump Debris in the The pump can be temporarily stuck due to contaminated heating is restarted water heating water normally V Replace the pump after cleaning the heating pipe 85 Navien America Inc 2010 CH series service Manual V

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