Navien NPE-240A Installation Manual
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Navien NPE-240A Installation Manual

Condensing water heater
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WARNING
If the information in these instructions is not followed exactly, a re or explosion may result, causing
property damage, personal injury, or death.
Do not store or use gasoline or other ammable vapors and liquids in the vicinity of this or any
–
other appliance.
WHAT TO DO IF YOU SMELL GAS
–
Do not try to light any appliance.
●
Do not touch any electrical switch; do not use any phone in your building.
●
Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
●
If you cannot reach your gas supplier, call the re department.
●
Installation and service must be performed by a quali ed installer, service agency or the gas
–
supplier.
The installation must conform with local codes or, in the absence of local codes, the National Fuel
–
Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Code.
When applicable, the installation must conform with the Manufactured Home Construction and
–
Safety Standard, Title 24 CFR, Part 3280 and/or CAN/CSA Z240 MH Series, Mobile Homes.
Condensing Water Heater
Installation
Manual
Model
NPE-180A/ 210A/ 240A
NPE-180S/ 210S/ 240S
Keep this manual near this water heater for future reference
whenever maintenance or service is required.
Certi ed for installation in a manufactured (mobile) home.
* The wetted surface of this product contacted by
consumable water contains less than one quarter of one
percent(0.25%) of lead by weight.
* Lead Free

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Summary of Contents for Navien NPE-240A

  • Page 1 Condensing Water Heater Installation Manual Model NPE-180A/ 210A/ 240A NPE-180S/ 210S/ 240S * Lead Free Keep this manual near this water heater for future reference whenever maintenance or service is required. Certi ed for installation in a manufactured (mobile) home. * The wetted surface of this product contacted by consumable water contains less than one quarter of one percent(0.25%) of lead by weight.

  • Page 2: Table Of Contents

    Contents 1. Safety Information 2. About the Water Heater 2.1 Items Included 2.2 Accessories 2.3 Specifications 2.4 The Front Panel 2.5 Components 2.6 Dimensions 2.7 Rating Plate 3. Installing the Water Heater 3.1 Choosing an Installation Location 3.2 Mounting the Water Heater to the Wall 3.3 Connecting the Gas Supply 3.4 Connecting the Water Supply 3.5 Connecting the Condensate Drain...

  • Page 3: Safety Information

    1. Safety Information The following safety symbols are used in this manual. Read and follow all safety instructions in this manual precisely to avoid DANGER unsafe operating conditions, fire, explosion, property damage, personal injury, or death. DANGER Indicates an imminently hazardous situation which, if not avoided, could result in severe injury or death.
  • Page 4 CAUTION WARNING 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.

  • Page 5: About The Water Heater

    2. About the Water Heater 2.1 Items Included 2.2 Accessories When you open the box, you will find the following items with the The following optional accessories are available for the water water heater. Check the box for each of the following items before heater: installing the water heater.

  • Page 6: Specifications

    The following table lists the s cations for the water heater. Additional speci cations about water, gas, electric, and air supplies (venting) appear in the Installation section. Item NPE-180A NPE-180S NPE-210A NPE-210S NPE-240A NPE-240S Natural Gas 15,000-150,000 BTU/H 19,900-180,000 BTU/H 19,900-199,900 BTU/H Heat Capacity (Input)

  • Page 7: The Front Panel

    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. Error Master Unit A code will appear on the display Cascade operation Hot Water Recirculation Display...

  • Page 8: Components

    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. Exhaust Duct Exhaust Limit Temperature Sensor Intake Air Duct Exhaust Body Fan Motor Ignition Transformer Burner Dual Venturi Primary Heat Exchanger...
  • Page 9 Exhaust Duct Exhaust Limit Temperature Sensor Intake Air Duct Exhaust Body Fan Motor Ignition Transformer Burner Dual Venturi Primary Heat Exchanger Gas Pipe Secondary Heat Exchanger APS (Air Pressure Sensor) Freeze Protection Switch Front Panel Condensate Trap Gas Valve PCB Box Flow Sensor Water Adjustment Valve Mixing Valve...

  • Page 10: Dimensions

    2.6 Dimensions The following diagrams show the dimensions of the water heater and the table lists the supply connections. Supply Connections Description Diameter Air Intake 2" Exhaust Gas Vent 2" Hot Water Outlet 3/4" Recirculation Inlet 3/4" Cold Water Inlet 3/4"...
  • Page 11 Supply Connections Description Diameter Air Intake 2" Exhaust Gas Vent 2" Hot Water Outlet 3/4" Cold Water Inlet 3/4" Gas Inlet 3/4" Condensate Outlet 1/2" Overhead View Supply Connections 1.5" (38mm) 14.3" (364mm) 4.5"(115mm) 6.7"(170mm) 2.3" 11.3" (60mm) (289mm) 17.3" (440mm) [NPE-180S/ 210S/ 240S] About the Water Heater...

  • Page 12: Rating Plate

    à des altitudes de 0 à 4,500 pieds (1,370 m) conformément aux toutes les procédures d’installation à haute altitude CAN/CGA 2.17 à une pression normale. Pour les installations à élévations en haut de 4,500 pieds, appeler le bureau de Navien.

  • Page 13: Installing The Water Heater

    Installing the water heater in a location without a drain gas, water, and electrical supplies. Carefully consider the following will void the warranty and Navien will not be responsible for factors when choosing an installation location: water damages that occur as a result. For more information about condensate drainage, refer to “3.5 Connecting the Condensate...

  • Page 14: Mounting The Water Heater To The Wall

    Adequate installation clearances Install the water heater in an area that allows for service and Navien water heaters come with an upper mounting bracket that is maintenance access to utility connections, piping, filters, and traps. pre-drilled at 16 inches on center for easy installation on standard Based on the installation location, ensure the following clearances wall studs.

  • Page 15: Connecting The Gas Supply

    Do not attempt a field conversion of this water heater Gas Inlet Adapter without a Navien gas conversion kit. Doing so will result in dangerous operating conditions and will void the warranty. Navien recommends connecting the water heater as the first water heater downstream of the gas meter, to ensure a sufficient gas supply.
  • Page 16 1/4"~3/8" Pipe flexible line has no crimps or tight bends in it, as Gas Pipe this will restrict gas flow. When using rigid pipe, Navien recommends the ● installation of a union on the gas supply line Full size Gas Pipe...
  • Page 17 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 ) per Hour (0.60 Specific Gravity; 0.5" WC Pressure Drop). Contact your gas supplier for BTU/ft3 ratings. Use 1,000 BTU/ft3 for simplified calculations.
  • Page 18 Maximum Liquefied Propane Delivery Capacity in Thousands of BTU/H (0.5" WC Pressure Drop) Length (including fittings) Pipe Size 100' 125' 150' 175' 200' 250' (3m) (6m) (9m) (12m) (15m) (18m) (24m) (30m) (38m) (45m) (53m) (60m) (76m) 1/2" 3/4" 1" 1,150 1 1/4"...

  • Page 19: Connecting The Water Supply

    Open a hot water faucet. The water heater should turn on and When the water heater reaches its maximum firing rate, check the gas in the gas supply line will be purged. the inlet gas pressure reading on the manometer. The gas pressure must fall within the ranges specified on page 18.
  • Page 20 3.4.2 Selecting a Recirculation Mode ("A" model Recirculation Line Expansion only) Tank On all “A“ model Navien water heaters, you can choose from [NPE-180A/ 210A/ 240A] two pre-heating modes: internal recirculation mode or external recirculation mode. To select a recirculation mode, you must set NPE-180S/210S/240S ●...
  • Page 21 Internal Recirculation Mode The following diagram shows the internal recirculation flow for pre-heating: To use the internal recirculation mode: Connect the water supply. Primary Heat Exchanger Set the 2-way valve inside the water heater to “INT. “ Buffer Secondary Heat Exchanger Tank Flow 2-Way...
  • Page 22 3.4.3 External Pump Wire Connection Set the front panel DIP switches at the far left (set of ten) to: 1—OFF; 2—ON. 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.
  • Page 23 Remove the 2 screws holding the PCB box in place and remove Locate the 10-switch DIP(SW1) on the front panel and turn on the PCB box from the system. the proper switches based on the desired recirculation setting (see Recirculation Dipswitch Settings below). Remove Screws here.
  • Page 24 Hot Water Pressure relief valve Domestic Recirculation Return Recirculation Using Two Pumps (Navien Internal Pump & External Pump) Shut-off Valve Hot water Cold water 3.4.4 Connecting a Pressure Relief Valve When installing the valve, follow these guidelines: WARNING Ensure that the discharge capacity of the pressure relief valve ●...

  • Page 25: Connecting The Condensate Drain

    From the water heater directly into an external drain. b. From the water heater, through a neutralizing agent, and then The Navien Condensing Water Heater creates condensation when into an external drain. it operates. This condensation has an acidic pH of 3-5. Follow all...

  • Page 26: Venting The Water Heater

    If you Navien also recommends installing a new vent system with this must install the water heater in an area with contaminated air, appliance. If reusing an existing vent system, thoroughly inspect use direct venting to supply air from outside the building.
  • Page 27 Description Canadian Direct Vent Installations US Direct Vent Installations Clearance above grade, veranda, porch, deck, or balcony 12 in (30 cm) 12 in (30 cm) Clearance to window or door that may be opened 36 in (91 cm) 12 in (30 cm) Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61 cm)
  • Page 28 4" (H) or 5" (H) or 5" (H) or will not be covered by the Navien warranty. If there is any question area of 1 in , per 3" round 3" round 3"...
  • Page 29 Canadian Non-Direct Vent US Non-Direct Vent Description Installations Installations Clearance above grade, veranda, porch, deck, or balcony 12 in (30 cm) 12 in (30 cm) 48 in (120 cm) below or to side Clearance to window or door that may be opened 36 in (91 cm) of opening;...
  • Page 30 This water heater has a built-in control to limit the exhaust ● temperature to 149°F (65°C). As a result, the Navien water heater can be vented with Schedule 40 PVC. If the incoming The Maximum Length does not include any elbows.
  • Page 31 3.6.4 Terminating the Vent Non-concentric Sidewall Venting – Air is drawn from a different ● location at a minimum of 12" (300mm) from the exhaust Before installing the water heater, determine what type of vent termination. Try to minimize the length of the intake air pipe termination is appropriate for the installation location and with this venting.
  • Page 32 Combustion Air Vent When installing a water heater outdoors, follow these guidelines: The Navien Outdoor Vent Kit must be used to ensure proper ● operation of the water heater. Ensure that there is plenty of clearance around the air intake and ●...

  • Page 33: Connecting The Power Supply

    3.7 Connecting the Power Supply 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 WARNING of DIP switches that control the functionality of the water heater. Set the DIP switches appropriately, based on the installation Improperly connecting the power supply can result in electrical environment.
  • Page 34 Remark 1-OFF; 2-OFF; 3-OFF * Intelligent Preheating: No Recirculation Recirculation Mode- Learns the user's hot water Internal Recirculation 1-ON; 2-OFF; 3-OFF Internal Navien usage patterns and starts Pump ("A" model preheating prior to an External Recirculation 1-OFF; 2-ON; 3-OFF only) anticipated draw.

  • Page 35: Installing A Cascading System

    4. Installing a Cascading System 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 additional considerations that are specific to installing cascading systems.

  • Page 36: Connecting The Communication Cables

    4.2 Connecting the Communication Cables When plumbing a cascading system, consider the following pipe Up to 16 water heaters can be connected with Navien Ready-Link diameters and flow rates. Note that flow rates above 6.6 ft/s may communication cables. Select one of the water heaters in the cause pipe erosion.
  • Page 37 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. Repeat step 2 to configure the rest of the slave water heaters in the system.

  • Page 38: Appendixes

    WARNING This conversion kit shall be installed by a quali ed service agency* in accordance with Navien America’s instructions and all applicable codes and requirements of the authority having jurisdiction. The information in these instructions must be followed to minimize the risk of re or explosion or to prevent property damage, personal injury or death.
  • Page 39 Figure 3. Detaching Gas Valve from could result in damage to the valve, causing potential severe Gas Inlet Pipe and Fan Motor Assembly personal injury, death or substantial property damage. Navien water heaters are shipped ready to fire natural gas ONLY. Appendixes...
  • Page 40 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. Replace the gas inlet pipe to its original position and use all screws to secure all connections.
  • Page 41 Table 2 at high re, do not NPE-210A adjust the gas valve. Check for the proper Gas Ori ce. NPE-210S 10.2 10.8 DANGER NPE-240A NPE-240S 10.2 10.8 Improper gas valve settings can cause severe personal injury, death or substantial property damage. Table 2. CO and CO value values must be within 0.5% of the values listed.)
  • Page 42 At high re, do not check the o set value and never adjust NPE-210S NAC-200 -0.04"±0.01" the gas valve. NAC-03 -0.02"±0.01" NPE-240A NPE-240S DANGER NAC-300 -0.04"±0.01" Table 3. O set value for low re Improper gas valve settings can cause severe personal injury, death or substantial property damage.
  • Page 43 5.1.1 Setting the Operation Mode Using the Front Panel, press and hold the Diagnostics Button for over 5 seconds until “1.TST” is displayed. Press the + (Up) button once to change the display to “2.OPR”. Press the Information Button once to acess the Operation Mode menu.

  • Page 44: Technical Data

    5.2 Technical Data Pressure Drop Curve Water Flow (GPM) [NPE-240A/ 240S] Water Flow (GPM) [NPE-210A/ 210S] Water Flow (GPM) [NPE-180A/ 180S] Appendixes...
  • Page 45 Outlet Flow Data 12.0 11.0 10.0 △T -Temperature Rise (℉) [NPE-240A] 11.0 10.0 △T -Temperature Rise (℉) [NPE-210A] 10.0 △T -Temperature Rise (℉) [NPE-180A] At altitudes above 2,000 ft (610m), the outlet ow will be reduced by 4% for each 1,000 ft (305 m) of altitude gain.
  • Page 46 Outlet Flow Data 13.0 12.0 11.0 10.0 △T -Temperature Rise (℉) [NPE-240S] 12.0 11.0 10.0 △T -Temperature Rise (℉) [NPE-210S] 10.0 △T -Temperature Rise (℉) [NPE-180S] At altitudes above 2,000 ft (610m), the outlet ow will be reduced by 4% for each 1,000 ft (305 m) of altitude gain. Note Appendixes...

  • Page 47: Wiring Diagram

    5.3 Wiring Diagram [NPE-180A/ 210A/ 240A] Appendixes...
  • Page 48 [NPE-180S/ 210S/ 240S] Appendixes...

  • Page 49: Ladder Diagram

    5.4 Ladder Diagram NEUTRAL EXT_PUMP Relay 1 FILTER VENTURI Relay 2 Relay 3 IGNITER Relay 4 PUMP Primary Primary SMPS Speed Control DC15V Secondary DC24V DC12V Water Adjust 200V FSA Power Valve DC5V Switch Flow Control Flame Rod Flow Sensor H.T.L WD-PSS Hall Sensor...
  • Page 50 NEUTRAL EXT_PUMP Relay 1 FILTER VENTURI Relay 2 Relay 3 IGNITER Relay 4 PUMP Primary Primary SMPS Speed Control DC15V Secondary DC24V DC12V 200V FSA Power DC5V Switch Water Mixing Water Adjust Valve Valve Flame Rod Flow Sensor H.T.L WD-PSS Hall Sensor Outlet Driving Circuit...

  • Page 51: Component Assembly Diagrams And Parts Lists

    5.5 Component Assembly Diagrams and Parts Lists 5.5.1 Case Assembly Appendixes...
  • Page 52 Description Part # Remark Intake Air Duct Assembly 30008662A Intake Air Filter 30008745A 20020393A NPE-180A 20019078A NPE-210A/240A Case 20026560A NPE-180S 20026559A NPE-210S/240S Air Pressure Sensor 30010346A Panel Bracket 20018388A 30008678A NPE-180A/210A/240A Cover NPE-180S/210S/240S 30011694A Case Lower Bracket 20007643B 30011969A Power Switch 30009482A Front Panel 30008333A...
  • Page 53 5.5.2 Burner Assembly(NPE-180A/ 210A/ 240A) 17-1 11-1 Appendixes...
  • Page 54 Description Part # Remark 30009189A NPE-180A 30010812A NPE-210A Heat Exchanger Assembly NPE-240A 30008780A Fan O-Ring (G50) 20003019A Fan Bracket(F) 20022095A Flow Sensor Assembly 30008571A Thermistor 30008366A Fan Braket(R) 20022096A 30009166A NPE-180A Cold Inlet Pipe 30010805A NPE-210A 30008446A NPE-240A 20006947A O-Ring (Φ17.5x2.7t)
  • Page 55 5.5.3 Burner Assembly(NPE-180S/ 210S/ 240S) 10 4 10 5 Appendixes...
  • Page 56 Description Part # Remark Ignition Transformer 30010455A Fan Bracket (R ) 20022096A Thermistor 30009478A Exhaust 30011706A NPE-180S Heat Exchanger Assembly 30011705A NPE-210S 30011704A NPE-240S Ignitor 30008591A Packing (Φ26.5x2.4t) 20006868A 30011519A NPE-180S Heat Exchanger Outlet Pipe 30011515A NPE-210S/240S WPA-C (Screw) 20026780A Fastner 20017726A O-Ring (Φ17.5x2.7t)
  • Page 57 5.5.4 Waterway Assembly(NPE-180A/210A/240A) 12-5 12-4 12-2 12-3 12-1 Description Part # Remark Bu er Tank 30010953A Hot Water Outlet Pipe Assembly 30008338A Pipe Adapter 30008349A O-RING (P20) 20017212A Thermistor (Red) 30008366A O-RING (P16) 20017210A Pipe Clip 20007733A Return Pipe Assembly 30008350A Pipe adapter 30008349A...
  • Page 58 Description Part # Remark O-RING (P20) 20017212A O-RING (P19) 20017211A Water Filter 30008351A Pipe Clip 20007733A Circulation Pump 30010346A Pump Air Seperator 30006831A Drain Plug 30003550B O-RING (P18) 20006947A Fastner 20017726A Water adjustment valve (WAV) 30008245A WAV Outlet Pipe Assembly 30008624A O-Ring (P16) 20011438A...
  • Page 59 5.5.5 Waterway Assembly(NPE-180S/ 210S/ 240S) Appendixes...
  • Page 60 Description Part # Remark Bracket 20026489A Thermistor 30008366A Water Filter 30008351A Cold Water Inlet Adapter 30011597A O-Ring (P15) 20017217A Fastner 20007859A Flow Sensor 30011534A O-Ring (P16) 20017210A Flow Sensor Outlet Adapter 20025959A Outlet Adapter 20025961A Fastner 20017726A Water Adjustment Valve (WAV) 30011532A Inlet Adapter 20025962A...
  • Page 61 5.5.6 Fan(Gas) Assembly Appendixes...
  • Page 62 Description Part # Remark Gas Adapter 30008431A 30009211A NPE-180S/180A Gas Pipe NPE-210S/210A/240S/240A 20018431A Gas Connector 20018430A Gas Valve 30008429A Gas Inlet Adapter 30008382A Fan Assembly 30008834A 30009219A NPE-180S/180A Dual Venturi 30008909A NPE-210S/210A/240S/240A NPE-180S/180A 20019142A Silence 20023829A NPE-210S/210A/240S/240A 20023861A NPE-180S/180A Silence Adapter NPE-210S/210A/240S/240A 20019141A O-Ring (P20)

  • Page 63: Installation Check List

    Owner’s Manual. If you have additional questions or need assistance with installation, contact Technical Support at 1-800-519-8794 or 1-949-420-0420, or refer to the technical support section of Navien’s website (www.navienamerica.com). Installing the Water Heater Have you maintained the required clearances from building openings and intake air vents?
  • Page 64 Connecting a Pressure Relief Valve 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" (150-300mm) of the floor? Connecting the Condensate Drain Have you installed a condensate drain line from the water heater to a drain or laundry tub? Venting the Water Heater...

  • Page 65: Requirements For The State Of Massachusetts

    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) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall...
  • Page 66 Memo...
  • Page 68 ● Serial number ● Date purchased ● Installation location and type ● Error code, if any appears on the front panel display. ● Version: 3.00(April 30. 2013) Navien America, Inc. 20 Goodyear lrvine, CA 92618 TEL +949-420-0420 FAX +949-420-0430 www.navienamerica.com...

This manual is also suitable for:

Npe-210aNpe-180aNpe-180sNpe-210sNpe-240s30012634a

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