1. DL manuals
  2. Navien
  3. Water Heater
  4. NCB-180
  5. Installation & Operation Manual

Navien NCB-180 Installation & Operation Manual

Manual is about: Condensing Boiler

Summary of NCB-180

  • Page 1

    Navien america, inc. 20 goodyear lrvine, ca 92618 tel +949-420-0420 fax +949-420-0430 www.Navienamerica.Com getting service if your ncb boiler requires service, you have several options for getting service: ● contact technical support at 1-800-519-8794 or on the website: www.Navienamerica.Com. For w...

  • Page 2: Ncb-180/ 210/ 240

    Model ncb-180/ 210/ 240 installation & operation manual * lead free h keep this manual near this boiler for future reference whenever maintenance or service is required. * the wetted surface of this product contacted by consumable water contains less than one quarter of one percent(0.25%) of lead by...

  • Page 3

    2 requirements for the state of massachusetts notice before installation this appliance must be installed by a licensed plumber or gas fitter in accordance with the massachusetts plumbing and fuel gas code 248 cmr sections 2.00 and 5.00. Important: in the state of massachusetts (248 cmr 4.00 & 5.00)...

  • Page 4: Contents

    Contents 3 contents safety information 4 1. About the boiler 7 1.1 items included 7 1.2 accessories 7 1.3 specifications 8 1.4 components 10 1.5 dimensions 12 1.6 rating plate 13 2. Installing the boiler 14 2.1 choosing an installation location 14 2.2 mounting the boiler to the wall 16 3. Installing...

  • Page 5: Safety Information

    4 safety information the following safety symbols are used in this manual. Read and follow all safety instructions in this manual precisely to avoid unsafe operating conditions, fire, explosion, property damage, personal injury, or death. Danger indicates an imminently hazardous situation which, if ...

  • Page 6

    Safety information 5 caution ● do not turn on the boiler unless the water and gas supplies are fully opened. Doing so may damage the boiler. ● do not turn on the water if the cold water supply shut- off valve is closed. Doing so may damage the boiler. ● do not use this boiler for anything other than...

  • Page 7

    6 safety information danger this boiler’s water temperature is set to 120°f (49°c) at the factory for your safety and comfort. Increasing the temperature increases the risk of accidental scalding. Water temperatures at or above 125°f (52°c) can cause instant scalding, severe burns, or death. Before ...

  • Page 8: 1.    About The Boiler

    About the boiler 7 1.1 items included when you open the box, you will find the following items with the boiler. Check the box for each of the following items before installing the boiler. Installation & operation manual, user’s information manual quick installation manual wall mounting bracket tappi...

  • Page 9

    8 about the boiler 1.3 specifications the following tables list the specifications for the boiler. Additional specifications about water, gas, electric, and air supplies (venting) appear in the installation section. Space heating specifications navien combination boiler space heating ratings model n...

  • Page 10

    About the boiler 9 general specifications item ncb-180 ncb-210 ncb-240 dimensions 17 in (w) x 28 in (h) x 12 in (d) weight 74 lbs (34 kg) 84 lbs (38 kg) 84 lbs (38 kg) installation type indoor wall-hung venting type forced draft direct vent ignition electronic ignition natural gas supply pressure (f...

  • Page 11

    10 about the boiler 1.4 components the following diagram shows the key components of the boiler. Component assembly diagrams and particular parts lists are included in the appendixes. Intake air air filter mixing chamber front panel exhaust flue duct ignitor & flame rod auto feeder (make-up water) c...

  • Page 12

    About the boiler 11 air vent fan & motor ignition transformer dual venturi premix burner air pipe primary heat exchanger gas pipe secondary heat exchanger circulation pump flow sensor pressure sensor (lwco) 3-way valve dhw inlet filter (with built-in flow restrictor) space heating supply dhw inlet s...

  • Page 13

    12 about the boiler 1.5 dimensions the following diagrams show the dimensions of the boiler and the table lists the supply connections. 27.4" (695m m ) 28.8 ” ( 731m m ) supply connections description diameter a air intake 2 in b exhaust gas vent 2 in c space heating supply 1 in d space heating retu...

  • Page 14

    About the boiler 13 1.6 rating plate the navien ncb boilers come from the factory configured for use with natural gas (ng). Before starting the installation , check the rating plate located on the side of the boiler to ensure that the boiler matches the gas type, gas pressure, water pressure, and el...

  • Page 15

    14 installing the boiler 2.1 choosing an installation location when choosing an installation location, you must ensure that the location provides adequate clearance for the boiler, adequate venting and drainage options, and sufficient access to gas, water, and electrical supplies. Carefully consider...

  • Page 16

    Installing the boiler 15 clearance from: indoor installation top 9 in (229 mm) minimum back 0.5 in (13 mm) minimum front 4 in (100 mm) minimum sides 3 in (76 mm) minimum bottom 12 in (300 mm) minimum clean, debris and chemical-free combustion air ● do not install the boiler in areas where dust and d...

  • Page 17

    16 installing the boiler 2.2 mounting the boiler to the wall navien ncb boilers come with an upper mounting bracket that is pre-drilled at 16 in (400 mm) on center for easy installation on standard wall studs. If the strength of the wall is insufficient or if the framing is non-standard or uneven, r...

  • Page 18

    Installing the system piping 17 prior to connecting plumbing to the boiler, flush the entire system to ensure it is free of sediment, flux, solder, scale, debris or other impurities that may be harmful to the system and boiler. During the assembly of the heating system, it is important to keep the i...

  • Page 19

    18 installing the system piping oxygen elimination this boiler may only be installed in a pressurized closed-loop heating system, free of air (oxygen) and other impurities. To avoid the presence of oxygen, ensure all of the air is removed from the system during commissioning via strategically placed...

  • Page 20

    Installing the system piping 19 back-flow preventer install a backflow preventer valve in the make-up water supply to the unit as required by local codes. Expansion tank an expansion tank must be installed in the space heating piping to prevent excessive pressure from building in the system. See the...

  • Page 21

    20 installing the system piping when installing the pressure relief valve, follow these guidelines: ● ensure that the valve’s discharge capacity is equal to or greater than the maximum pressure rating of the boiler’s space heating system. ● ensure that the maximum btu/h rating on the pressure relief...

  • Page 22

    Installing the system piping 21 contaminant maximum allowable level total dissolved solids (tds) 500 mg/l zinc 205 mg/l navien is not responsible for plugging of the domestic system by scaling or accumulation of dirt; suitable steps shall be taken by the installer and user to avoid water quality rel...

  • Page 23

    22 installing the system piping if necessary, replace the factory-installed flow restrictor with one that satisfies your flow requirements. Follow these instructions to replace the flow restrictor. 1. Locate the cold water inlet adapter on the bottom of the unit. 2. Turn the knob counterclockwise to...

  • Page 24

    Installing the system piping 23 when installing pressure relief valve, follow these guidelines: ● ensure that the valve’s discharge capacity is equal to or greater than the maximum pressure rating of the boilers dhw system. ● ensure that the maximum btu/h rating on the pressure relief valve is equal...

  • Page 25

    24 installing the system piping before connecting the condensate drain, choose one of the following disposal options: a b c d a. From the boiler directly into an external drain b. From the boiler, through a neutralizing agent, and then into an external drain note if you choose this option, the neutr...

  • Page 26

    Installing the system piping 25 3.4 system fill connection before filling the boiler, remove the air vent cap to allow the system to fill properly. Replace the cap when the system is full. Air vent cap note ensure that the vent cap is re-installed before testing or operating the system. 3.4.1 built-...

  • Page 27

    26 installing the system piping 3.6 examples of system applications refer to the following examples to properly implement a system for space heating, dhw supply, or both. These examples are provided to suggest basic guidelines when you install the boiler system. However, the actual installation may ...

  • Page 28

    Installing the system piping 27 thermostat configuration for the air handler interface set the pcb dip sw2 #7 to down position (off) to use a thermostat with the air handler. 1 2 3 4 5 6 on 1 2 3 4 5 6 7 8 on refer to the following diagram for wiring connections. Cn23 cn10 cn24 cn25 common hot therm...

  • Page 29

    28 installing the system piping 3.6.2 system application - zone system with zone valves additional zone zone #2 zone #1 system circulator air separator expansion tank not to exceed 4 pipe dia or max. 12" zone valve (typical) note ● system application drawings are intended to explain the system pipin...

  • Page 30

    Installing the system piping 29 3.6.3 system application - zone system with circulators additional zone zone #2 zone #1 system circulator air separator expansion tank not to exceed 4 pipe dia or max. 12" check valve note ● system application drawings are intended to explain the system piping concept...

  • Page 31

    30 installing the system piping 3.6.4 system application - air handler system air separator expansion tank air flow air handler note ● the boiler performs automatically system application drawings are intended to explain the system piping concept only. ● refer to 3.4 system fill connection on page 2...

  • Page 32

    Connecting the gas supply 31 warning ● before connecting the gas supply, determine the gas type and pressure for the boiler by referring to the rating plate. Use only the same gas type indicated on the rating plate. Using a different gas type will result in abnormal combustion and malfunction of the...

  • Page 33

    32 connecting the gas supply typical lp gas piping examples: single regulator system gas regulator (12” wc) 1 / 4 ”~ 3 / 8 ” pipe full size gas pipe gas tank full size gas pipe 2 lb system with multiple regulators gas regulator (2 lb) 12” wc 2 psi 1 / 2 ”~ 3 / 8 ” pipe 1 / 2 ” pipe gas tank full siz...

  • Page 34

    Connecting the gas supply 33 4.1 gas pipe sizing tables the following tables are referenced from 2012 national fuel gas code for reference only. Please consult the gas pipe manufacturer for actual pipe capacities. Maximum natural gas delivery capacity in cubic feet (ft 3 ) per hour (0.60 specific gr...

  • Page 35

    34 connecting the gas supply maximum liquefied propane delivery capacity in thousands of btu/h (0.5 in wc pressure drop) pipe size length (including fittings) 10 ft (3 m) 20 ft (6 m) 30 ft (9 m) 40 ft (12 m) 50 ft (15 m) 60 ft (18 m) 80 ft (24 m) 100 ft (30 m) 125 ft (38 m) 150 ft (45 m) 175 ft (53 ...

  • Page 36

    Connecting the gas supply 35 6. Re-open the manual gas valve and check for leaks. 7. Open multiple fixtures that have high flow rates, such as bathtub and shower faucets, to ramp the boiler up to its maximum firing rate. 8. When the boiler reaches its maximum firing rate, check the inlet gas pressur...

  • Page 37: 5.    Venting The Boiler

    36 venting the boiler warning improper venting of the boiler can result in excessive levels of carbon monoxide, which can lead to severe personal injury or death. This boiler must be vented in accordance with the “venting of equipment” section of the latest edition of the ansi z223.1/nfpa 54 natural...

  • Page 38

    Venting the boiler 37 ref description canadian direct vent installations 1 us direct vent installations 2 a clearance above grade, veranda, porch, deck, or balcony 12 in (30 cm) 12 in (30 cm) b clearance to window or door that may be opened 36 in (91 cm) 12 in (30 cm) c clearance to permanently clos...

  • Page 39

    38 venting the boiler 2. Provide two openings to allow for circulation of combustion air as specified by ansi z223.1/nfpa 54 or can/cga b-149.1: ncb-180 ncb-210 ncb-240 maximum input (btu/h) 150,000 180,000 199,000 outdoor make up air is provided, a minimum free area of 1 in 2 , per 4,000 btu/h 40 i...

  • Page 40

    Venting the boiler 39 ref description canadian non-direct vent installations 1 us non-direct vent installations 2 a clearance above grade, veranda, porch, deck, or balcony 12 in (30 cm) 12 in (30 cm) b clearance to window or door that may be opened 36 in (91 cm) 48 in (120 cm) below or to side of op...

  • Page 41

    40 venting the boiler 5.2 selecting vent pipe materials venting requirements differ in the us and canada. Consult the following chart or the most recent edition of ansi z223.1/nfpa 54 or can/cga b149.1, as well as all applicable local codes and regulations when selecting vent pipe materials. Do not ...

  • Page 42

    Venting the boiler 41 indoor boiler installation venting examples the following are some possible indoor venting options: ● 2 in or 3 in two-pipe sidewall venting 12" (300mm) min. 12" (3 00mm ) min. Exhaust gas exhaust gas intake air exterior view intake air intake air 5.4 terminating the vent befor...

  • Page 43

    42 venting the boiler ● 2 in or 3 in two-pipe vertical venting – intake and exhaust pipes do not have to terminate in the same area. 12" (300mm) min. 12" (300mm) min. 36" (900mm) min. 12" (300mm) min from any obstruction (above, below, left, or right) exhaust gas intake air ● concentric roof venting...

  • Page 44

    Setting the dip switches 43 caution do not remove the front cover unless the power to the boiler is turned off or disconnected. Failure to do so may result in electric shock. The boiler has 2 sets of dip switches on the main circuit board (pcb) and 2 sets of dip switches on the front panel. Dip swit...

  • Page 45

    44 setting the dip switches dip switch 2 (set of 2) the dip sw 2 on the front panel configures the gas type settings. Before changing the settings, lift the rubber cover to access the front panel dip switches. 1 2 3 4 5 6 7 8 9 10 1 2 on on 2 on ng lp 2 on switch function setting 2 gas type natural ...

  • Page 46

    Connecting the power supply 45 warning improperly connecting the power supply can result in electrical shock and electrocution. Follow all applicable electrical codes of the local authority having jurisdiction. In the absence of such requirements, follow the latest edition of the national electrical...

  • Page 47

    46 installation check list after installing the boiler, review the following checklist. You should be able to answer “yes” to all of the items in the checklist. If not, review the appropriate sections to complete the installation. To troubleshoot any operational problems refer to “troubleshooting” i...

  • Page 48

    Installation check list 47 connecting a pressure relief valve yes no have you installed an approved pressure relief valve on the boiler? Does the rating of the pressure relief valve match or exceed the maximum btu rating of the boiler? Is the pressure relief valve 3 / 4 in on the hot water outlet an...

  • Page 49

    48 installation check list pcb dip switch setting (dip sw 2, set of 8) yes no is switch #1 set correctly for return water control (on) or supply water control (off)? Unless continuous boiler operation is required, is switch #7 in the up (on) position? Unless using the exhaust thermostat, is switch #...

  • Page 50: 9.    Operating The Boiler

    Operating the boiler 49 2. Press the + (up) or – (down) buttons until the desired temperature appears on the display. Mode you can adjust the temperature while the display is flashing. Once the display stops flashing, the temperature setting is stored. Note ● take note of the original heating temper...

  • Page 51

    50 operating the boiler 9.3 viewing basic information to view information about the boiler, press the mode button three times. “info” will appear on the display. Mode press the + (up) or – (down) buttons to switch between the information types. Display description psi o/r s r space heating supply wa...

  • Page 52

    Operating the boiler 51 display description psi o/r s r outdoor air temperature (°f) (with optional outdoor temperature sensor only) psi o/r s r outdoor reset curve -: not in use. 1: finned tube baseboard 2: fan coil 3: cast iron baseboard 4: low mass radiant 5: high mass radiant 6: radiator 7: cust...

  • Page 53

    52 operating the boiler this mode is used to configure the outdoor reset control mode. This mode is disabled by default from the factory. Caution an outdoor sensor error may occur if the outdoor reset control mode is enabled without the outdoor sensor installed note in the outdoor reset control mode...

  • Page 54

    Operating the boiler 53 outdoor low temperature setting range range remarks -4°f (-20°c) ~ [outdoor high temperature set-point - 9°f (5°c)] default: 14°f (-10°c) setting the highest outdoor temperature display description psi o/r s r highest outdoor temperature (°f) psi o/r s r highest outdoor tempe...

  • Page 55

    54 operating the boiler setting the pump freeze protection temperature display description psi o/r s r pump freeze protection temperature (°f) this menu is used to configure the circulation pump freeze protection temperature. When the space heating supply temperature stays below the set value for lo...

  • Page 56

    Operating the boiler 55 setting the burner-off temperature display description psi o/r s r burner-off temperature (°f) during space heating, the boiler turns off the burner when the space heating supply temperature meets or exceeds the burner-off temperature. Burner-off temperature range range remar...

  • Page 57

    56 operating the boiler setting the return absolute max temperature display description psi o/r s r return absolute max set point (°f) this menu may be used to make changes to the maximum return temperature range when the return control mode is in use. When configuring the custom mode in the outdoor...

  • Page 58

    Operating the boiler 57 setting a new password display description psi o/r s r changing password this menu may be used to set a new password to access the parameter setting menu. To set a new password: 1. Move to [t.Psc] and press the [mode] button. The current password is displayed, with the first ...

  • Page 59: 10.    Appendixes

    58 appendixes 10.1 gas conversion this boiler is configured for natural gas from the factory. If conversion to propane gas is required, the conversion kit supplied with the boiler must be used. Warning this conversion kit shall be installed by a qualified service agency* in accordance with navien am...

  • Page 60

    Appendixes 59 6. Loosen the three screws indicated in the figure. 7. Remove the pcb assembly. 8. With the internal components exposed, locate the gas inlet pipe and the gas valve in the middle of the unit, as shown in figure 2. Gas valve gas inlet pipe figure 2. Ncb series internal components 9. Use...

  • Page 61

    60 appendixes once the gas orifice is exposed, remove the two screws that hold the part in place. Remove the gas orifice from its housing and prepare the new gas orifice for the lp conversion for installation. Remove two 2 screws here figure 4. Access to gas orifice in fan assembly warning ● do not ...

  • Page 62

    Appendixes 61 240lp 240ng figure 6. Orifice identification replace the old orifice piece with the new part for use with lp gas. Ensure that the orifice is properly seated inside the port before proceeding to the next step. 11. Replace the gas inlet pipe to its original position and use all screws to...

  • Page 63

    62 appendixes 16. Measure and adjust the gas/air ratio. Option 1. Using combustion analyzer (recommended) a. Loosen the screw, rotate the plate and remove the gasket to access the emissions monitoring port as shown in figure 7. B. Insert the analyzer into the port (figure 7). Figure 7. Insert the an...

  • Page 64

    Appendixes 63 c. Fully open a hot water fixture and set the boiler to operate at 1-stage min mode (refer to table 2). Measure the offset value at low fire and compare it to the values in table 3. If the offset value is out of range, the gas valve set screw will need to be adjusted. If adjustment is ...

  • Page 65

    64 appendixes 10.2 wiring diagram color c ode b o r w y bk br gy : blue : or ange : r ed : w hit e : y ello w : black : br own : gr een/y ello w if an y of the or ig inal wir es as supplied the boiler must be replac ed , they must be r eplac ed their equiv alen t. Fm fan m ot or y bk r o w cn8 cn18 ...

  • Page 66

    Appendixes 65 10.3 ladder diagram hot neutral venturi relay 1 relay 2 relay 3 relay pwm fan speed control 24v output 220v flame rod dc15v dc24v dc12v dc5v mcu 1 h.T.L wd-pss driving circuit relay 3 mgv1 mgv2 relay 1 relay 2 relay 4 relay 5 communication interface uart communication interface ready l...

  • Page 67

    66 appendixes 10.4 component assembly diagrams and parts lists 10.4.1 case assembly 2 1 4 5 6 7 8 3.

  • Page 68

    Appendixes 67 # description part # remark 1 intake air duct assembly 30008662b 2 exhaust pipe assembly 30008673a 3 case 20027375a 4 intake air filter 20007668a 5 air pressure sensor 30010346a 6 pcb 30012262a 7 front panel 30012269a 8 cover 30012276a.

  • Page 69

    68 appendixes 10.4.2 burner assembly 1 2 9 10 11 11 13 14 21 18 17 4 20 13 19 12 10 16 15 3 6 5 7 8.

  • Page 70

    Appendixes 69 # description part # remark 1 damper 30008825a 2 o-ring (g50) 20003019a 3 fan bracket 20022095a 4 siphon 30012280a 5 burner chamber ass'y 30010353a ncb-180 30008440a ncb-210/240 6 igintion transformer 30010455a 7 burner packing 20021677a ncb-180 20021672a ncb-210/240 8 heat exchanger a...

  • Page 71

    70 appendixes 10.4.3 waterway assembly a a 24 8 4 2 14 3 9 15 16 17 10 11 12 2 3 6 28 3 19 2 36 21 32 3 33 30 24 23 19 35 27 35 19 26 25 30 29 6 34 13 22 21 3 20 19 35 31 35 19 18 3 2 1 3 22 # description part # remark 1 dhw heat exchanger 30008181a ncb-180 30005017a ncb-210/240 2 thermistor 3000836...

  • Page 72

    Appendixes 71 # description part # remark 7 dhw outlet adpator 30003747a 8 dhw flow sensor 30012033a 9 o-ring (p14) 20006952a 10 dhw cold water adaptor 30010317a 11 o-ring (p20) 20017212a 12 dhw cold water filter - 13 air vent 30012277a 14 auto fill valve 30012241a 15 o-ring (p16) 20011438a 16 fastn...

  • Page 73

    72 appendixes 10.4.4 fan (gas) assembly 2 4 7 5 6 11 14 12 11 10 9 13 11 15 1 3 8.

  • Page 74

    Appendixes 73 # description part # remark 1 fan assembly 30008834a 2 fan packing 20022744a 3 o-ring (g75) 20018079a 4 dual venturi 30009219a ncb-180 30008909a ncb-210/240 5 silence 20019142a ncb-180 20023829a ncb-210/240 6 silence adaptor 20023861a ncb-180 20019141a ncb-210/240 7 venturi packing 200...

  • Page 75

    74 appendixes 10.6 outdoor reset control (available with optional outdoor temperature sensor) the outdoor reset control feature may be used to enhance energy efficiency while maintaining optimal heating performance. With the outdoor reset control, the space heating temperature setting automatically ...

  • Page 76

    Appendixes 75 outdoor temperature sensor installation guidelines heat load supply set-point range return set-point range finned tube baseboard (default) 120-180°f (48.5-82°c) 101-147°f (38-63.5°c) fan coil 140-180°f (60-82°c) 116-147°f (46.5-63.5°c) cast iron baseboard 100-170°f (37.5-76.5°c) 86-139...

  • Page 77: Memo

    Memo.