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  5. Installation Manual

Navien NPE-180A Installation Manual

Manual is about: NPE series Condensing Water Heaters

Summary of NPE-180A

  • Page 1

    Warning if the information in these instructions is not followed exactly, a fire or explosion may result, causing property damage, personal injury or death. Do not 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 ...

  • Page 2: Contents

    2 contents 1. Safety information 3 2. About the water heater 5 2.1 items included 5 2.2 accessories 5 2.3 specifications 6 2.4 the front panel 7 2.5 components 8 2.6 dimensions 11 2.7 rating plate 13 3. Installing the water heater 14 3.1 choosing an installation location 14 3.2 mounting the water he...

  • Page 3: 1.    Safety Information

    Safety information 3 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 4

    4 safety information caution do not turn on the water heater unless the water and gas supplies are fully opened. Doing so may damage the water heater. Do not turn on the water if the cold water supply shut- off valve is closed. Doing so may damage the water heater. Do not use this water heater for a...

  • Page 5

    About the water heater 5 2.1 items included when you open the box, you will find the following items with the water heater. Check the box for each of the following items before installing the water heater. Installation & operation manual quick installation manual wall mounting bracket tapping screws...

  • Page 6

    6 about the water heater 2.3 specifications the following table lists the specifications for the water heater. Additional specifications about water, gas, electric, and air supplies (venting) appear in the installation section. Item npe-150s npe-180a npe-180s npe-210a npe-210s npe-240a npe-240s heat...

  • Page 7

    About the water heater 7 a b c d e f g h i j k 2.4 the front panel the front panel allows you to adjust the water temperature and view the operating status or error codes. Remove the protective sheet from the front panel before using it. A error g master unit a code will appear on the display cascad...

  • Page 8

    8 about the water heater 2.5 components the following diagram shows the key components of the water heater. Component assembly diagrams and particular parts lists are included in the appendixes. Intake air duct exhaust duct exhaust limit temperature sensor exhaust body ignition transformer burner pr...

  • Page 9

    About the water heater 9 intake air duct exhaust duct exhaust limit temperature sensor exhaust body ignition transformer burner primary heat exchanger secondary heat exchanger flow sensor condensate trap front panel pcb box mixing valve water inlet filter condensate drain fitting condensate drain li...

  • Page 10

    10 about the water heater intake air duct exhaust duct exhaust limit temperature sensor exhaust body ignition transformer burner primary heat exchanger secondary heat exchanger flow sensor condensate trap front panel pcb box mixing valve water inlet filter condensate drain fitting condensate drain l...

  • Page 11

    About the water heater 11 2.6 dimensions the following diagrams show the dimensions of the water heater and the table lists the supply connections. 27.4 in (695 mm) 28.8 in (731 mm) supply connections description diameter a air intake 2 in b exhaust gas vent 2 in c hot water outlet 3 / 4 in d recirc...

  • Page 12

    12 about the water heater 27.4 in (695 mm) 28.8 in (731 m m ) supply connections description diameter a air intake 2 in b exhaust gas vent 2 in c hot water outlet 3 / 4 in d cold water inlet 3 / 4 in e gas inlet 3 / 4 in f condensate outlet 1 / 2 in overhead view 3 in (77 mm) 6.7 in (170 mm) 4.5 in ...

  • Page 13

    About the water heater 13 2.7 rating plate water heaters 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 water heater to ensure that the water heater matches the gas type, gas pressure, water pressure...

  • Page 14

    14 installing the water heater 3.1 choosing an installation location when choosing an installation location, you must ensure that the location provides adequate clearance for the water heater, adequate venting and drainage options, and sufficient access to gas, water, and electrical supplies. Carefu...

  • Page 15

    Installing the water heater 15 3.2 mounting the water heater to the wall navien water heaters come with an upper mounting bracket that is pre-drilled at 16 in 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 unev...

  • Page 16

    16 installing the water heater to connect the gas supply: 1. Determine the gas type and pressure for the water heater by referring to the rating plate. 2. Perform a pressure test on the main gas supply line. 3. Purge the gas line of any debris. 4. Determine the proper size and type for the gas line....

  • Page 17

    Installing the water heater 17 note tighten the water heater connection valves with care to avoid damage. The gas connection fitting on all water heaters is 3 / 4 in. 1 / 2 in rigid pipe can be used; refer to the sizing tables on the proceeding pages for limitations. Avoid using 1 / 2 in corrugated ...

  • Page 18

    18 installing the water heater 3.3.1 gas pipe sizing tables (referenced from 2012 national fuel gas code) these tables are 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 grav...

  • Page 19

    Installing the water heater 19 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 (5...

  • Page 20

    20 installing the water heater 8. When the water heater reaches its maximum firing rate, check the inlet gas pressure reading on the manometer. The gas pressure must fall within the ranges specified on page 19. 3.4 connecting the water supply the water fittings on the water heater are 3 / 4 in. If t...

  • Page 21

    Installing the water heater 21 3.4.1 using the water heater for combination water heating and space heating when using the water heater for both water (potable) heating and space heating, follow these guidelines: ensure that all piping and components connected the water heater are suitable for potab...

  • Page 22

    22 installing the water heater caution do not remove recirculation cap. (internal recirculation mode) the following diagram shows the internal recirculation flow for pre-heating: internal recirculation mode primary heat exchanger secondary heat exchanger buffer tank flow sensor domestic water supply...

  • Page 23

    Installing the water heater 23 3.4.3 external pump wire connection an external pump may be connected to the water heater for recirculation applications. When selecting a circulator, it shall be sized to maintain a flow of 2-4 gpm through the water heater. Follow the instructions below when connectin...

  • Page 24

    24 installing the water heater 8. Locate the 10-switch dip (sw1) on the front panel and turn on the proper switches based on the desired recirculation setting (see recirculation dipswitch settings below). 1 2 3 1 2 4 5 6 7 8 9 10 on on 9. Turn on the switch beside the front panel. 10. Put the water ...

  • Page 25

    Installing the water heater 25 to complete the installation of the water heater, you must install an approved 3 / 4 in, maximum 150 psi pressure relief valve on the hot water outlet. The water heater has a built-in high temperature shut off switch, so install a “pressure only“ relief valve. This val...

  • Page 26

    26 installing the water heater 3.5 connecting the condensate drain the navien condensing water heater creates condensation when it operates. This condensation has an acidic ph of 3-5. Follow all local codes and regulations when disposing of condensate from the water heater. We recommend draining the...

  • Page 27

    Installing the water heater 27 3.5.1 condensate neutralizer kit warning to avoid damaging the appliance, the neutralizer inlet and discharge must be lower than the condensate drain. Do not allow exhaust flue gases to vent through the neutralizer. Leakage can cause injury or death from carbon monoxid...

  • Page 28

    28 installing the water heater 3.6 venting the water heater warning improper venting of the water heater can result in excessive levels of carbon monoxide, which can lead to severe personal injury or death. This water heater must be vented in accordance with the “venting of equipment“ section of the...

  • Page 29

    Installing the water heater 29 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 permane...

  • Page 30

    30 installing the water heater 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: maximum input (btu/h) outdoor make up air is provided, a minimum free area of 1 in 2 per 4,000 btu/h indoor make up air is provided, a minimum fre...

  • Page 31

    Installing the water heater 31 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 s...

  • Page 32

    32 installing the water heater 3.6.3 measuring vent length the maximum vent length when using 2 in exhaust ducts is 60 ft. The maximum vent length when using 3 in vent ducts is 150 ft. The intake duct length can be of equal length to the exhaust duct length. Both maximum lengths are reduced by the n...

  • Page 33

    Installing the water heater 33 3.6.4 terminating the vent before installing the water heater, determine what type of vent termination is appropriate for the installation location and situation. The subsections that follow describe some typical venting configurations, but do not include all possible ...

  • Page 34

    34 installing the water heater 2 in or 3 in two-pipe vertical venting – intake and exhaust pipes do not have to terminate in the same area. 12 in (300 mm) min. 12 in (300 mm) min. 36 in (900 mm) min. 12 in (300 mm) min. From any obstruction (above, below, left, or right) exhaust gas intake air conce...

  • Page 35

    Installing the water heater 35 3.8 setting the dip switches the water heater has two dip switch locations: on the main circuit board (pcb) and on the front panel. Each location has two sets of dip switches that control the functionality of the water heater. Set the dip switches appropriately, based ...

  • Page 36

    36 installing the water heater 10-switch panel: switch function setting remark 1-3 recirculation mode- internal navien pump ("a" model only) no recirculation 1-off; 2-off; 3-off * intelligent preheating: learns the user's hot water usage patterns and starts preheating prior to an anticipated draw. P...

  • Page 37

    Installing a cascading system 37 when installing a cascading system, carefully consider the design of the system and the features of the installation location. Follow all local codes and regulations, as well as all guidelines for installing the water heater. The following sections describe additiona...

  • Page 38

    38 installing a cascading system note the table above is based on model npe-240a. 4.2 connecting the communication cables up to 16 water heaters can be connected with navien ready-link communication cables. Select one of the water heaters in the cascading system as the master water heater, and then ...

  • Page 39

    Installing a cascading system 39 2. On the slave water heater, press and hold the diagnostic and down(-) buttons for more than 2 seconds. “sl.01” will appear on the display to confirm that this water heater is set as a slave. 3. Repeat step 2 to configure the rest of the slave water heaters in the s...

  • Page 40: 5.    Appendixes

    40 appendixes 5.1 gas conversion this water heater is configured for natural gas from the factory. If conversion to propane gas is required, the conversion kit supplied with the water heater must be used. Warning this conversion kit shall be installed by a qualified service agency* in accordance wit...

  • Page 41

    Appendixes 41 6. 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 n...

  • Page 42

    42 appendixes danger see figure 5. Inspect the o-ring between the gas valve and gas valve inlet adapter whenever they are disassembled. The o-ring must be in good condition and must be installed. Failure to comply will cause a gas leak, resulting in severe personal injury or death. Lp npe-150s npe-1...

  • Page 43

    Appendixes 43 1 2 ng 1 2 lp 1 2 3 1 2 4 5 6 7 8 9 10 on on danger when conversion is required, be sure to set the front panel dip switches according to the supply gas type. Failure to properly set the dip switches could cause carbon monoxide poisoning, resulting in severe personal injury or death. 1...

  • Page 44

    44 appendixes d. Fully open several hot water fixtures and set the water heater to operate at 2-stage max mode (refer to page 45). Measure the co 2 value at high fire. If the co 2 values do not match table 2 at high fire, do not adjust the gas valve. Check for the proper gas orifice. Danger improper...

  • Page 45

    Appendixes 45 5.1.1 setting the operation mode 1. Using the front panel, press and hold the diagnostics button for over 5 seconds until “1.Tst” is displayed. 2. Press the + (up) button once to change the display to “2.Opr”. 3. Press the information button once to acess the operation mode menu. 4. Pr...

  • Page 46

    46 appendixes 5.2 technical data pressure drop curve 2t gu uw tg . Qu u ru k 9cvgt(nqy)2/ [npe-240a/ 240s] 2 tg uuwtg . Q uu r uk 9cvgt(nqy)2/ [npe-210a/ 210s] 2 tg uuwtg . Quu r uk 9cvgt(nqy)2/ [npe-180a/ 180s] 2 tg uuwtg . Quu r uk 9cvgt(nqy)2/ [npe-150s].

  • Page 47

    Appendixes 47 outlet flow data (nqy )2/ ů66gorgtcvwtg4kugș [npe-240a] ( nqy)2/ ů66gorgtcvwtg4kugș [npe-210a] (nqy )2 / ů66gorgtcvwtg4kugș [npe-180a] note at altitudes above 2,000 ft (610 m), the outlet flow will be reduced by 4% for each 1,000 ft (305 m) of altitude gain..

  • Page 48

    48 appendixes outlet flow data (nqy ) 2/ ů66gorgtcvwtg4kugș [npe-240s] (nqy )2/ ů66gorgtcvwtg4kugș [npe-210s] (nqy )2/ ů66gorgtcvwtg4kugș [npe-180s] (nqy )2 / ů66gorgtcvwtg4kugș [npe-150s] note at altitudes above 2,000 ft (610 m), the outlet flow will be reduced by 4% for each 1,000 ft (305 m) of al...

  • Page 49

    Appendixes 49 5.3 wiring diagram c on5 c on6 c on7 c on8 c on10 c on1 c on4 c on2 c on3 c on11 tb1 bk bk f ront p anel bk bk bk bk bk bk bk bk bk bk bk bk h igh limit s/w aps r w bk air p ressur e s ensor f lo w sensor r w bk b b inlet1 t hermist o r b b b b outlet2 t hermistor b b b b inlet2 t herm...

  • Page 50

    50 appendixes power switch con5 con6 con7 con8 con10 con1 con4 con2 con3 con11 tb1 bk bk bk bk bk bk bk bk bk bk bk bk bk bk high limit s/w aps r w bk air pressure sensor flow sensor r w bk b b inlet1 thermistor b b b b outlet2 thermistor b b b b inlet2 thermistor b b b b outlet1 thermistor b b b b ...

  • Page 51

    Appendixes 51 5.4 ladder diagram hot neutral venturi relay 1 relay 2 relay 3 relay 4 igniter pump speed control primary mcu 1 mcu 2 dc24v flow sensor aps dc12v fan water adjust valve flow control dc15v uart communication interface ready link interface ready link fan hall sensor outlet thermistor 2 i...

  • Page 52

    52 appendixes hot neutral venturi relay 1 relay 2 relay 3 relay 4 igniter pump speed control primary mcu 1 mcu 2 dc24v flow sensor aps dc12v fan water adjust valve dc15v uart communication interface ready link interface ready link fan hall sensor outlet thermistor 2 inlet thermistor 1 inlet thermist...

  • Page 53

    Appendixes 53 5.5 component assembly diagrams and parts lists 5.5.1 case assembly 12 7 13 8 9 10 18 2 1 3 4 6 5 17 16 15 14 11.

  • Page 54

    54 appendixes # description part # remark 1 intake air duct assembly 30008662b 2 intake air filter 20007667a 3 case 20019078c npe-180a/210a/240a 20026559b npe-150s/180s/210s/240s 4 air pressure sensor 30010346a 5 panel bracket 20018388a 6 cover 30008678b npe-180a/210a/240a 30011694a npe-150s/180s/21...

  • Page 55

    Appendixes 55 5.5.2 burner assembly(npe-180a/ 210a/ 240a) 7 6 18 13 3 7-1 10 9 12 8 14 11 12 4-1 6-1 4 12 17-1 11-1 12 12 1 15 17 12 6 6-1 14 5 2 17 6-1 6-1 6-1 6-1.

  • Page 56

    56 appendixes # description part # remark 1 heat exchanger assembly 20018362a npe-180a 30008780a npe-210a/240a 2 fan packing 20022744a 3 fan bracket (f) 20022095a 4 flow sensor assembly 30008571a 4-1 thermistor 30008366a 5 fan braket (r) 20022096a 6 cold inlet pipe 30009166a npe-180a 30008446a npe-2...

  • Page 57

    Appendixes 57 5.5.3 burner assembly(npe-150s/ 180s/ 210s/ 240s) 10 4 10 5 3 2 13 12 1 18 17 10 15 23 9 10 10 14 6 20 9 10 7 10 9 24 16 21 10 17 15 10 6 9 10 25 19 22 8 9 10 11.

  • Page 58

    58 appendixes # description part # remark 1 ignition transformer 30010455a 2 fan bracket (r ) 20022096a 3 thermistor 30009478a exhaust 4 heat exchanger assembly 30214351a npe-150s 30011706a npe-180s 30011705a npe-210s 30011704a npe-240s 5 ignitor 30214183a npe-150s 30012226a npe-180s/210s/240s 6 pac...

  • Page 59

    Appendixes 59 5.5.4 waterway assembly(npe-180a/ 210a/ 240a) 1 15 16 8 3 10 9-2 9-3 11 7 8-2 4-1 8-1 3-5 9-1 3-2 3-1 5 2 12 2-4 2-3 2-1 4-2 2-5 2-2 8-3 12 13 14 8-4 9-3 7-1 12-1 12-2 12-3 12-4 12-5 11 6 9 11 17 3-3 3-4 4-3 11 4 5 2-4 # description part # remark 1 buffer tank 30010953a 2 hot water out...

  • Page 60

    60 appendixes # description part # remark 3-2 o-ring (p20) 20017212a 3-3 o-ring (p19) 20017211a 3-4 water filter 30008351a 3-5 pipe clip 20007733a 4 circulation pump 30010346a 4-1 pump air seperator 30006831a 4-2 drain plug 30003550b 4-3 o-ring (p18) 20006947a 5 fastner 20017726a 6 water adjustment ...

  • Page 61

    Appendixes 61 5.5.5 waterway assembly(npe-180s/ 210s/ 240s) 10 15 2 12 6 6 13 8 14 11 10 11 8 9 11 8 12 11 17 16 8 6 7 6 5 4 3 2 1 6 10 15 2 12 6 6 13 8 14 11 10 11 8 9 11 8 12 11 17 16 8 6 7 6 5 4 3 2 1 6.

  • Page 62

    62 appendixes # description part # remark 1 bracket 20026489a 2 thermistor 30008366a 3 water filter 30008171a 4 cold water inlet adapter 30011597a 5 o-ring (p15) 20017217a 6 fastner 20007859a 7 flow sensor 30011534a 8 o-ring (p16) 20017210a 9 flow sensor outlet adapter 20025959a 10 outlet adapter 20...

  • Page 63

    Appendixes 63 5.5.6 fan(gas) assembly 98 95 9 10 94 97 12 9 11 99 9 10 93 9 15 9 10 91 9 13 9 14 96 92 [npe-180s/ 180a/ 210s/ 210a/ 240s/ 240a] 6 12 11 7 16 13 3 10 2 10 10 5 14 8 4 [npe-150s].

  • Page 64

    64 appendixes # description part # remark 1 gas adapter 30009921a npe-180s/180a 30009922a npe-210s/210a/240s/240a 2 gas pipe 30014329a npe-150s 30013323a npe180s/180a 30008431a npe-210s/210a/240s/240a 3 gas connector 20018430a 4 gas valve 30008429a 5 gas inlet adapter 20023809a 6 fan assembly 300154...

  • Page 65

    Appendixes 65 5.6 installation check list after installing the water heater, 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 t...

  • Page 66

    66 appendixes connecting a pressure relief valve yes no have you installed the pressure relief valve on the hot water outlet pipe near the water heater? Have you installed a discharge drain tube from the pressure relief valve to within 6–12 in (150–300 mm) of the floor? Connecting the condensate dra...

  • Page 67

    Appendixes 67 5.7 navien comfortair+ add-on controller kit (optional) the navien comfortair+ is an add-on controller for the navien npe-a series water heaters. It adds input and output functions to the npe-a series water heaters for a combination application where space heating and domestic hot wate...

  • Page 68

    68 appendixes 5.8 navien on-demand control kit (optional) navien on demand control kit is an add-on input board for the navien npe-a series water heaters. It adds signal input functions to the npe-a series water heaters for more efficient dhw hot water recirculation functionality. With the on demand...

  • Page 69

    Appendixes 69 5.9 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 ...

  • Page 70: Memo

    Memo.

  • Page 71

    Getting service if your water heater requires service, you have several options for getting service: contact technical support at 1-800-519-8794 or on the website: www.Navien.Com. For warranty service, always contact technical support first. Contact the technician or professional who installed your ...