Navien 35k DIY repair

If heating or hot water supply does not work in a wall-mounted gas boiler, then there is a high probability of failure of the three-way tap. All work on the repair of gas equipment must be carried out by specialized organizations that have a license. Self-repair of the gas boiler is prohibited. If the three-way valve fails, it is recommended to call a specialist to replace it. But the old three-way valve can be repaired by yourself and left as a backup.

A three-way valve serves to redirect the flow of water. When the hot water supply tap opens, the heated water flows through it into the mixer. And when the tap is closed, the water is redirected through the heat exchanger to the heating system.

In the article, using the example of a malfunction of the three-way valve of the Navien gas boiler, we will describe possible breakdowns of the three-way valve, methods of checking for subsequent repair. A crane costs from 3 to 5 thousand rubles, depending on the region, and spare parts for repairs are ten times cheaper (except for the engine). Readers are given the opportunity not only to learn about the device of this part, but also to try their hand at repair. After all, except for a Phillips screwdriver, a tester and a soldering iron, nothing is required. The most important thing is care, accuracy and observe electrical safety measures, since the motor of the three-way crane is powered by an alternating voltage of 220 V.

So, we have a non-working three-way valve for the Navien gas boiler, which was successfully replaced by a new valve by specialists.

It can be seen that the inside is covered with rust. This happens when an additional filter for water purification has not been installed in the system, and its quality is poor. At a minimum, the tap will have to be disassembled and completely cleaned. But first things first.

First, unscrew the four screws on the valve body using a regular Phillips screwdriver.

Three-way valve of the navien boiler with an electric drive - remove the engine.

We disassemble the case in half. In the case, we see two microswitches. We check them with a multimeter. In the normal position, they are closed, and when pressed, they open. The appearance, position and dimensions of the switches may differ depending on the modification of the crane. If one of the microswitches is defective, replace them with a soldering iron. Sometimes, to determine if one of the switches is faulty, you may not need a multimeter. Often the malfunction is visible visually, the button sinks in one position, does not work clearly.

Checking the microswitches of a three-way motorized valve.

To check the motor, unscrew two more screws. The three-way valve can now be completely disassembled.

Disassembled three-way valve.

Having disconnected the wires, we take out the engine for checking.

Photo of a three-way crane motor.

Before checking the motor, check the resistance between the terminals. It should be about 15 kOhm. If the resistance is measured in Ohms or infinite, then immediately replace the engine, as it burned out. This happens due to the ingress of water inside it. If the resistance is normal, then power the motor with an alternating voltage of 220V.

Attention, observe safety measures during work. There is a risk of electric shock.

If the motor is spinning (very slowly, 3 rpm), then it is serviceable. If not, then you can disassemble it. Remove the cover after pressing the four latches. Inside, in addition to the engine, a gearbox is assembled. If, when removing the gears, the motor does not work, then replace the motor assembly.And if it works, then carefully examine the plastic gears, perhaps one of them is damaged.

With any repair of a three-way valve, it is necessary to carry out preventive cleaning from rust and replace all O-rings to be sure of its correct operation. After cleaning, the valve is assembled in reverse order.

Navien boiler three-way valve, assy.

After assembling the valve, be sure to re-energize the motor. Visually see that the stem moves. Otherwise, repeat the entire check procedure again.

Today we'll talk about long-burning solid fuel boilers, pyrolysis and pellet boilers, let's try to figure out if they are so good. What is it.

The article provides information on the causes of the malfunction, methods of determining the breakdown and repair of the tube with the turbocharged condensate collector.

Requirements for the room in which the gas boiler will be installed. What should be the boiler room? Questions of ceiling height, volume.

What kind of ignition options are provided in modern boiler equipment? Detailed consideration of piezo ignition and electric ignition. Which option is more.

The question often arises of how to heat a greenhouse, garage or other outbuildings. If it is not possible, connect to the city boiler room, then.

The gas heater is popular today among apartment owners and private houses. It is functional, efficient, and workflows are fully automated.

The heaters of the Korean company Navien are in the lead in this series. Components and electronics are manufactured in Korea and Japan, which guarantees their high reliability.

The gas boiler Navien is equipped with a self-diagnosis and protection system, which simplifies maintenance and repair, and also increases the safety of operation. In the event of a serious malfunction, the automation will independently turn off the boiler or warn the user about possible problems.

The Navien double-circuit gas heating device stands out among a huge number of competitors for its compactness and attractive design.

Even if low-quality gas is used, subject to the requirements and recommendations of the manufacturer, the Navien gas boiler will delight the owner with reliable and long-term work of carrying out complex and expensive repairs.

Gas boiler Navien is able to maintain functionality with voltage drops of up to 30%, a drop in gas and water pressure in the supply lines. Navien boilers, regardless of type, are equipped with systems that guarantee uninterrupted operation in various operating conditions. The anti-freeze system will prevent water from freezing during the cold season.

The control system is intuitive and adjustable remotely. The construction uses steel heat exchangers, which guarantee high efficiency and long service life.

The air pressure sensor used in the circuit ensures complete combustion of the fuel, which leads to cost savings. The water heating mode is turned on simultaneously with the opening of the hot water tap. The burner is automatically turned on, and when the tap is closed, the system is put into standby mode. The boiler only heats water for the heating system. The winter-summer mode automatically switches the system to DHW or vice versa.

Gas boiler design

The Navien boiler has a closed combustion chamber. The coaxial smoke exhaust system excludes the ingress of combustion products into living quarters.

A wide range of temperature settings, both room and hot water, makes the Navien boiler competitive even with representatives from high price categories.

The Navien company supplies products in several series, differing primarily in the installation method:

• Outdoor. This type is mainly used for installation in private houses, since it requires a separate room. The power of the units produced in two series ranges from 11 to 60 kW.
• Wall mounted.These are used everywhere due to their compactness, simplicity of design and unpretentiousness. These boilers are presented in five series versions with power from 10 to 40 kW.

The designs of the Navien boilers are not much different. They are double-circuit with a closed-type combustion chamber (except for the ATMO series). The only difference is in the electronic equipment, in terms of control.

The advantages of the equipment are as follows:

• Room temperature sensor and remote control, including on some models using a smartphone.
• Surge protection by installing an innovative SMPS chip.
• Built-in frost protection system.
• Use of stainless steel heat exchangers.

The disadvantages of a gas heater, including the Navien boiler, include the need for an uninterrupted power supply. The manufacturer recommends installing a UPS.

The internal structure of the gas boiler

It is recommended to install, connect and first turn on in the presence of representatives of gas services. Installation is carried out by certified specialists. Otherwise, repairs can cost a pretty penny.

It is allowed to carry out the installation on its own, but with careful adherence to the manufacturer's instructions. A responsible part of this work is the correct selection and installation of the smoke exhaust system.

Heater operations are described in detail in the instructions. Learning the positions is fundamental to the flawless operation of the device.

Despite the highest reliability, like any other complex equipment, the Navien boiler needs repairs from time to time. It is recommended to contact the service.

Navien service centers offer a wide range of services, including the following types of work:

• Diagnostics with subsequent full or partial replacement of units.
• Repair of units.
• Installation and post-warranty service.
• Cleaning radiators and pipes from scale and other deposits using special compounds.
• Replacement of consumables, gaskets and fasteners.

Some "breakdowns" are eliminated on their own.

To do this, you need to correctly recognize the cause of the malfunction and correctly assess your own knowledge and possible consequences. The built-in diagnostic system can help with this. The device displays codes - alphanumeric readings that indicate a particular failure.

So code 01e means that the equipment has overheated. This can happen due to pump failure or blockage of pipelines. In this case, check the condition of the pump impeller for integrity and jamming. They also check the resistance in the coil, that is, they reveal whether there was a short circuit. It is recommended to determine if there is airing. If so, the repair boils down to bleeding air from the system.

Code 03e signals an ignition problem. There are several reasons. This is an ionization sensor failure, a gas cut, or an open in the ground circuit. The flame sensor is cleaned of dirt with a needle, and the plaque on the electrode is removed with fine sandpaper.

There are about two dozen codes. The code table is attached to the instructions. If there is no code on the screen, but an unusual noise is heard, then this happens due to insufficient throughput of the pipes. Scale is formed due to poor quality coolant. It is drained and replaced with a new one.

They also reduce the temperature of heating the water. The boiler output may be too high for your system. Cleaning of the heat exchanger is recommended. If it does not work, the heat exchanger will have to be replaced.

The reasons for refusals are revealed things that are checked first on their own. For example, clean the filter or assess the integrity of the wiring, open valves, the presence of gas and water in the supply system, etc.

They categorically do not interfere with electronics, even if you have the appropriate education. This can only be done by the masters of a specific profile.

Some units and assemblies are changed or cleaned on their own. Spare parts are recommended to be ordered and purchased from Navien dealers.

Before opening the lid, it is recommended to disconnect the boiler from the water, gas and electricity supply. Here are some examples of replacement.

To replace the fan, and it changes only as a complete unit, you should:

• Disconnect the gas line.
• Remove the hose between the fan and the air sensor.
• Disconnect the connectors (there are two of them) connecting to the control unit.
• Unscrew the screws (3 pcs.) And remove the fan. Then install a new one and return everything to its previous state in the reverse order.

In the video, you can see the flushing of the Navien boiler:

If the main heat exchanger is changed, then this should be done as follows:

• First, remove the following units - gas supply line, ignition transformer, fan and overheating sensor.
• Then disconnect the ground, unscrew the fastening screws and remove the combustion chamber.
• Then unscrew the screws (8 pcs.) And remove the flue gas collector.
• After that, unscrew the screws holding the combustion chamber cover (9 pcs.) And unscrew the screws connecting the heat exchanger with the combustion chamber housing (6 pcs.)
• Pull out the heat exchanger and install a new one in reverse order.

If the heat exchanger is cleaned, there is no damage to it, then the old one is used. But be sure to check the integrity of the ceramic seal. Change it if necessary.

Gas boilers from the Korean company Navien are distinguished by a high level of reliability. They are able to work for years without bothering users with breakdowns. This is confirmed by numerous reviews from users and heating engineers. But they are also characterized by breakdowns, since there is nothing ideal in nature. Let's see what error 03 is in Navien boilers, how to decipher other types of errors and which nodes to check when these errors occur.

Automatic self-diagnosis systems, in conjunction with protection systems, prevent serious breakdowns at a very early stage. Detecting any errors, the electronics turns off the equipment, displaying a code on indicators or LCD screens. In the absence of self-diagnostics, troubleshooting is a little difficult, but in general, the algorithm for checking internal nodes remains approximately the same.

Self-diagnosis facilitates the troubleshooting of gas equipment in Navien boilers equipped with electronics. It polls numerous sensors and nodes, analyzing the results and storing them in internal memory. Critical errors are immediately displayed on the indicators. Self-diagnosis systems were originally created for specialists. But having at least a little experience in repairing boilers and straight arms, nothing prevents you from repairing Navien equipment yourself.

In order for you to be able to repair Navien gas boilers on your own, we have compiled this guide. It will provide invaluable assistance in eliminating breakdowns and failures. Let's see what the self-diagnostic systems can tell us - we will present the error codes of the Navien boiler in the form of a list:

Despite the huge number of possible breakdowns, most of them do not pose a serious problem and are resolved rather quickly and with little means.

• 01E - overheating has occurred in the equipment, as evidenced by the temperature sensor;
• 02E - in Navien boilers, error 02 indicates an open circuit in the flow sensor circuit and a decrease in the level of the coolant in the circuit;
• Error 03 in Navien boilers signals the absence of a flame signal. Moreover, the flame can burn;
• 04E - this code is the opposite of the previous one, as it indicates the presence of a flame in its absence, as well as a short circuit in the flame sensor circuit;
• 05E - the error occurs when the circuit for measuring the temperature of the coolant in the heating circuit is faulty;
• 06E - another temperature sensor breakdown code, indicating a short in its circuit;
• 07E - this error occurs when there is a malfunction of the temperature sensor circuit in the DHW circuit;
• 08E - error of the same sensor, but diagnosing a short circuit in its circuit;
• 09E - error 09 in Navien boilers indicates incorrect functioning of the fan;
• 10E - error 10 indicates problems with smoke exhaust;
• 12E - the flame in the burner has gone out;
• 13E - error 13 indicates a short circuit in the heating circuit flow sensor;
• 14E - code of lack of gas supply from the main;
• 15E is a rather ambiguous error indicating problems with the control board, but without specifying the faulty node;
• 16E - error 16 in Navien boilers occurs when the equipment overheats;
• 18E - malfunctions in the smoke exhaust system sensor (sensor overheating);
• 27E - the electronics registered errors in the air pressure sensor (APS).

There are no repair instructions included with the boilers, since a service company should be involved in the repair work. But nothing prevents us from repairing a faulty unit on our own, without resorting to the help of specialists. Let's see how the Navien boilers are repaired at home.

In order to prevent the appearance of scale, install a system for purifying and softening tap water - the costs will not be the greatest, but you will extend the life of your boiler.

First you need to clean the heat exchanger of the Navien gas boiler. At home, this is done with citric acid, toilet bowl cleaners, or special products (if available). We remove the heat exchanger, fill it with the selected composition, and then rinse it under high pressure of water.

A very complex error indicating some kind of malfunction or imperfection in the heating system. Try to correct the situation by adjusting the speed of the circulation pump, make sure that there is no airiness in the system. It is also necessary to check the filter and the heat exchanger lumen. In some cases, it may be necessary to replace the coolant.

For some reason, the electronics do not receive a signal about the presence of a flame. This may be due to a lack of gas supply or a malfunction of the flame sensor and its circuit. Sometimes the error appears after carrying out any work on the gas pipeline. Another possible reason is that the ignition does not work. Eliminating the error:

• We check the availability of gas supply;
• We check the efficiency of the ignition;
• We check the ionization sensor (it could get dirty).

When using liquid gas, it is recommended to check the operation of the reducer.

Let's look at the typical malfunctions of this series, especially since there are not so many of them. For example, in the Navien Ace 24 K model, error 10 often occurs. This gas wall-mounted double-circuit boiler is built according to a scheme with a closed combustion chamber, so there are often problems with the removal of smoke. The most common cause of a malfunction is a fan breakdown - it will need to be replaced.

Error 02 occurs no less often. It is this error that can appear when the Navien boiler quickly picks up temperature and cools down quickly. The reason lies in the airing of the circuit or in the malfunction of the flow sensor. The heating system must be free of air - for example, by connecting it to the water supply and driving the coolant under pressure. In our reviews, we have already written how the heating mains are vented.

In order to avoid damage to the board, we strongly recommend installing a voltage stabilizer in the power circuit of the Navien boiler.

The most unpleasant mistake, as it is difficult to understand something here. It is designated by code 15E. It is almost impossible to figure out the device of the board on your own, without having a specialized education. Therefore, we recommend calling a specialist. He will test the electronic board for faults, localize the breakdown and fix it. How testing and repairs will be carried out, at home or in a service center, will be determined by a specialist.

Let's see how to repair the Navien mounted boiler with our own hands or bring the floor model to life.To do this, we will briefly go through the above error codes and identify the troubleshooting algorithms.

Do not panic, as the reason for the display of this code may be the banal airing of the system and filter. It is necessary to bleed air from pipes and batteries using standard recommendations. The next step is to check the integrity of the circulation pump. Make sure that it is spinning, and that its impeller is normally driving the coolant through it. Sometimes the error occurs due to physical damage to the impeller. Worst of all, if the circulation pump fails, in this case it will have to be rewound or even purchased a new model.

In order to avoid problems with the circulation pump, we recommend purchasing a suitable model from the Grundfos brand.

We have already spoken about a malfunction with code 02 - it manifests itself as a rapid rise in temperature, followed by a drop. We also figured out the code 03. If the self-diagnosis system has displayed error 04, it is necessary to check the condition of the flame sensor and its circuit. Make sure the sensor does not touch other metal parts. Sometimes the appearance of this code is associated with a malfunction of the system board, it will need to be repaired or replaced.

Most often, control boards are still changed, than they are repaired. If you have any doubts about its performance, contact a specialist.

Also check the condition of the connecting wires - they should not be shorted or broken. For diagnostics, use the most common ohmmeter.

Here we need to diagnose the water temperature sensor in the heating circuit. Find data on its standard parameters, make sure they are consistent (resistance to a certain temperature).

Double-circuit boilers give us warmth and hot water. They are equipped with two circuits and two sets of sensors. For example, there are two temperature sensors at once. One measures the temperature in the heating circuit, the other measures the temperature of the hot water. And the codes presented above indicate a breakdown of the temperature sensor of the DHW circuit or a malfunction in its circuit. Diagnostics and repairs are carried out in the same way as in the previous section - using an ohmmeter and visual inspection.

Before us are typical Navien Ice boiler trouble codes, indicating problems with the fan. It is necessary to check the integrity of its windings and ring their resistance, diagnose the presence of an interturn short circuit. A broken fan must be replaced with a new one. If the fan turns out to be intact, you should test the control board - do it yourself, if you have the appropriate knowledge, or call a specialist from the service center.

As for error 10, it indicates difficulties in the operation of the smoke exhaust system. The fan may be to blame here, you also need to check the length of the chimney and make sure it is passable - cleaning will be required. Often the culprit is the incorrect operation of the air pressure sensor. Worst of all, if the error appears as a result of constant failures in the Navien boiler board. The simplest wind blowing into the chimney cannot be ruled out.

This code is typical for Navien Ice and Navien Ice Coaxial boilers. It manifests itself in the event of a short circuit in the sensor circuit, and also indicates problems with its performance. The sensor must be tested and, if faulty, replaced. We also check the connecting wires. In rare cases, the control board is at fault.

This code appears when the heating equipment overheats. There can be many reasons for this:

One of the rarest reasons for this error is an increase in the gas supply level. Check this parameter and, if necessary, screw on the valve.

• For some reason, the coolant has overheated;
• There is not enough coolant in the circuit;
• Malfunction of the control board;
• Malfunction of the three-way valve;
• The temperature control sensor in the DHW circuit has broken.

Check all components carefully and isolate the malfunction.

This code indicates overheating of the temperature sensor in the flue system. When it is triggered, the operation of the equipment is suspended. We check the patency of the chimney, check the sensor itself and the connecting circuits, make sure that there is no reverse draft. Incorrect operation of the control board is also possible, but this happens only in the most rare cases.

The last code in our review indicates a malfunction in the air pressure sensor circuit in the Navien Ice and Ice Coaxial models. We check all the connecting wires, change the sensor if necessary. As in all of the above cases, the appearance of a code is possible if the control board does not work correctly.

It may seem that the most unreliable node in Navien boilers, generating mountains of errors, is the control board. But this is far from the case - it breaks down quite rarely, while numerous sensors and wires break much more often. If you provide reliable protection for the electronics, your heating equipment will delight you with no breakdowns and a long service life. Study the errors of the Navien boiler and repair the faulty device with your own hands.

Repairing household equipment is costly. But it is not always necessary to call the master, in many cases you can do it on your own. Consider the instructions for repairing a gas boiler Navien.

Navien is a Korean-made heating equipment popular in Russia due to its good price / quality ratio.

These are the main design advantages of gas units:

• the control unit is equipped with a microprocessor chip with a function to protect the automation from power surges;
• automatic maintenance of the working mode, many settings;
• long service life;
• can operate on natural and liquefied gas;
• the pressure drop of the coolant is allowed up to 0.1 bar without equipment failure;
• the system does not freeze in the event of a gas interruption. In a normal situation, when the temperature drops to +5, the burner automatically turns on. If ignition is impossible, a forced circulation pump operates, this does not allow the coolant to freeze;
• easy intuitive adjustment of modes.

Diagram of the device of the gas boiler Navien.

The power of Navien gas boilers varies in the range of 11-37 kilowatts. The range of the brand includes wall-mounted (what are wall-mounted gas boilers for heating a house), floor-standing (floor-standing gas boilers for heating a house), condensing models (what is a condensing boiler), with open and closed chambers, as well as diesel units. Wall-hung boilers are equipped with corrosion-resistant high-carbon stainless steel heat exchangers.

Malfunctions of the Navien boiler are registered by the automation. Each error has a code that is shown on the display. Let's analyze the most common ones.

01E. Overheat. It can happen due to a blockage (the passage channel is narrowed), or due to malfunctions of the circulation pump.

02. Low coolant level, damage to the measuring device. In the first case, the system is aired. 02 may also indicate a breakdown of the pump impeller, a closed position of the control valve, or a malfunction of the flow sensor.

03E. Burner problems: no flame signal (types of gas burners for heating boilers). The error appears if there is no gas supply, the ignition does not work, the gas valve is closed, the ionization sensor does not work, and also if there is no proper grounding.

04E - a false signal about the presence of fire or a short circuit in the sensor circuit.

05E-08E. Broken circuit in the coolant temperature meter. Possible damage to the contact between the sensor and the controller or a short circuit in this area.

10E - smoke. This also happens due to fan problems (or poor contact of the sensor with the fan).The reason may also be a blockage of the chimney or wind in the chimney (how to make a chimney for a gas boiler correctly).

12E - the fire in the combustion chamber has gone out.

13E - short circuit in the flow meter.

14E - gas supply is interrupted.

15E - problems with the control board.

17E - DIP switch malfunction.

18E - overheating of the smoke exhaust device.

27E - air pressure sensor problems.

If the boiler is noisy during operation, and the error is not displayed on the display, the reason may be in scale, which impedes the flow of the coolant. The boiler makes noise when overheating, boiling water, or when the quality of the coolant is poor.

A frequent malfunction of a gas double-circuit wall-mounted boiler Navien is a failure of a three-way crane (what are wall-mounted double-circuit gas boilers for heating a house). This occurs, in particular, when the crane has reached the end of its service life (usually 4 years). In this case, hot water may disappear in the DHW circuit.

Consider how to eliminate the main malfunctions of a gas boiler. In case of error 01, you need to carefully inspect the pump, check the condition of the impeller, the electrical unit, clean the dirt filter, and also purge the air from the system.

To eliminate error 02 of the Navien boiler, perform the following actions:

• bleed air from the system;
• measure pressure;
• check the resistance on the pump coil, make sure there is no short circuit;
• check the position of the control valve, open if closed;
• clean the sensor flag.

Error 03 of the Navien boiler is often displayed if the flame sensor is clogged. It should be cleaned. The gray coating on the electrode is cleaned off with fine-grain sandpaper. When an error 5 appears, you need to check the condition of the circuit section between the sensor and the controller, in case of serious malfunctions, replace the sensor.

In case of error 10, the Navien boiler needs:

• check the fan for serviceability, replace if repair is impossible;
• check the contacts in the tubes of the measuring device;
• clean the chimney.

When error 13 appears, replace the sensor. The noise in the system can disappear after flushing the heat exchanger, sometimes it needs to be replaced. The taps should be opened completely; it is recommended to lower the temperature of the coolant.

Another important point in servicing the Navien gas boiler is how to fill the system again after draining. Such a need may arise after the repair / replacement of parts of the system or if the coolant was drained while the house was empty.

Before starting refueling, you need to de-energize the devices, turn off the gas. Check the position of valves, shut-off and distribution valves, open them to the maximum. Turn the make-up valve (usually at the bottom of the unit) to the left. Close when the pressure gauge shows 1.2-2 bar. If, as a result of filling, the alarm indicator is triggered, the water is drained and everything is done again.

Do-it-yourself repair of the Navien hinged boiler in many cases is possible and acceptable. In order to maximize the uptime of the unit, the manufacturer's instructions must be strictly followed during the installation and operation of the heating system.

For preventive purposes, it is advisable to supplement the system with several devices: a gas and water filter, a water converter (magnetic, polyphosphate). To protect sensitive electronics, it is recommended to connect the boiler through a voltage stabilizer (what are voltage stabilizers for heating boilers).

Video about disassembling the Navien boiler and cleaning the heat exchanger.