Navien NCB-180 Service Manual

Condensing Boiler
Service
Manual
Getting Service
If your boiler requires service, you have several options for getting service:
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Contact Technical Support at 1-800-519-8794 or on the website: www.navienamerica.com.
For warranty service, always contact Technical Support first..
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Contact the technician or professional who installed your boiler.
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Contact a licensed professional for the affected system (for example, a plumber or electrician).
When you contact Technical Support, please have the following information at hand:
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Model number
●
Serial number
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Date purchased
●
Installation location and type
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Error code, if any appears on the front panel display.
Version: 1.0(October. 27. 2013)
Navien America, Inc.
20 Goodyear lrvine, CA 92618 TEL +949-420-0420 FAX +949-420-0430 www.navienamerica.com

Navien NCB-180 Specifications

General

Fuel Type	Natural Gas or Propane
Maximum Input	180, 000 BTU/h
Minimum Input	18, 000 BTU/h
Heating Capacity	180, 000 BTU/h
Water Connection Size	3/4" NPT
Gas Connection Size	3/4" NPT
Vent Type	Direct Vent
Domestic Hot Water Flow Rate at 35°F	8.4 GPM
AFUE	95%
Vent Size	2 inch or 3 inch
Electrical Requirements	120V AC, 60Hz

Summary

Getting Service

1. Safety Information

1.4 Safety Precautions

Provides general safety precautions regarding flammable materials and vapors.

COMPROMISED VENTING SYSTEM

Precautions and checks for a compromised venting system to ensure safe operation.

WHAT TO DO IF YOU SMELL GAS

Instructions on what to do if you smell gas to prevent fire or explosion.

HOT WATER TEMPERATURE SETTING

INSTALLATION REQUIREMENTS

IMPORTANT SAFETY PRECAUTIONS

Provides crucial safety precautions for operating and servicing the Navien boiler.

GAS CONVERSION

General Warnings

General Cautions

2. Product Information

3. Technical Data

3.1 General Specifications

4. System Details

4.1 Setting the DIP Switches

4.1.1 Circuit Board DIP Switches

Circuit Board DIP Switches (Set of 8)

Front Panel DIP Switches (Set of 10)

Front Panel DIP Switches (Set of 2)

4.2 Measuring the Inlet Gas Pressure

4.3 Gas Conversion

Gas/Air Ratio Adjustment

4.4.3 Turning Boiler On or Off

4.4.5 Error Display and Reset

How to display and reset error codes on the boiler's front panel.

4.4.6 Adjusting Space Heating Temperature

4.4.7 Adjusting DHW Temperature

4.4.9 Error History Display

4.4.11 Special Parameter Mode

Instructions for accessing and modifying special parameter settings for boiler operation.

4.4.12 Factory Reset

4.6 Error Codes

List of error codes and their corresponding conditions for the boiler.

4.9 Key Components Description

4.9.1 PCB

4.9.2 High Limit Switch

4.9.3 Thermistor

4.9.4 Fan Motor

4.9.5 Flame Rod Assembly

4.9.6 Ignition Transformer

4.9.7 APS

4.9.8 Main Gas Valve

4.9.9 Burner

4.9.10 Flow Sensor

4.9.11 Primary Heat Exchanger

4.9.12 Secondary Heat Exchanger

4.9.13 DHW Heat Exchanger

4.9.14 Circulation Pump

4.9.15 3-Way Valve

4.9.16 Water Pressure Sensor

4.9.17 Auto feeder Valve

5. Troubleshooting

5.1 Error Code Classification

Classifies error codes by system, lists error codes, levels, functions, and actions.

5.2 Error Code List

Detailed list of error codes, their functions, and self-diagnostic/action steps.

5.2.1 003Error: Ignition Failure

Troubleshooting steps for ignition failure (Error E003).

5.2.2 004Error: False Flame Detection

Troubleshooting steps for false flame detection (Error E004).

5.2.3 012Error: Flame Loss

Troubleshooting steps for flame loss (Error E012).

5.2.4 016Error: Overheat

Troubleshooting steps for overheat (Error E016).

5.2.5 030Error: Exhaust Gas Temperature

Troubleshooting steps for exhaust gas temperature error (Error E030).

5.2.6 046Error: Heat Exchanger Thermistor

Troubleshooting steps for heat exchanger thermistor error (Error E046).

5.2.7 047Error: Exhaust Thermistor

Troubleshooting steps for exhaust thermistor error (Error E047).

5.2.8 060Error: Dual Venturi

Troubleshooting steps for Dual Venturi error (Error E060).

5.2.9 109Error: Fan Motor RPM

Troubleshooting steps for fan motor RPM error (Error E109).

5.2.10 110Error: Air Pressure

Troubleshooting steps for air pressure error (Error E110).

5.2.11 205Error: Heat Exchanger Output Sensor

Troubleshooting steps for heat exchanger output sensor error (Error E205).

5.2.12 218Error: Heat Exchanger Input Sensor

Troubleshooting steps for heat exchanger input sensor error (Error E218).

5.2.13 351Error: Auto Feeder Valve

Troubleshooting steps for abnormal auto feeder valve (Error E351).

5.2.14 352Error: High Water Pressure

Troubleshooting steps for high water pressure (Error E352).

5.2.15 353Error: Water Pressure Sensor

Troubleshooting steps for abnormal water pressure sensor (Error E353).

5.2.16 407Error: DHW Outlet Thermistor

Troubleshooting steps for hot water outlet thermistor error (Error E407).

5.2.17 421Error: Cold Water Inlet Thermistor

Troubleshooting steps for cold water inlet thermistor error (Error E421).

5.2.18 439Error: Flow Sensor

Troubleshooting steps for flow sensor error (Error E439).

5.2.19 515Error: PCB/Electrical Supply

Troubleshooting steps for PCB internal circuit error (Error E515).

5.2.20 517Error: DIP Switch Setting

Troubleshooting steps for DIP SW setting error (Error E517).

5.2.21 594Error: PCB Communication

Troubleshooting steps for abnormal PCB communication (Error E594).

5.2.22 615Error: Abnormal Signal Input

Troubleshooting steps for abnormal signal input by PCB (Error E615).

5.2.23 740Error: Outdoor Sensor

Troubleshooting steps for abnormal outdoor sensor (Error E740).

5.2.24 777Error: LWCO Installation

Troubleshooting steps for LWCO installation error (Error E777).

5.2.25 782Error: Panel Connection

Troubleshooting steps for front panel to PCB connection error (Error E782).

5.3 Troubleshooting guide by symptom

5.3.1 Noise Troubleshooting

5.3.2 Water Temperature Issues

5.3.3 Circuit Breaker Operation

6. Replacement of Parts

6.1 Replacement Procedure

6.2 Components Replacement Instructions

6.2.1 PCB

6.2.7 Main Gas Valve

8. Inspection and Maintenance Schedule

8.1 Annual Servicing