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Published: March 26, 2020
Reading time: 5 min
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Korean Navien gas boilers are characterized by the highest degree of reliability. They work for many years without bothering the owners with breakdowns.
This is confirmed by user reviews and conclusions by heat power specialists, which can be found on the Internet in the public domain. Malfunctions of Navien boilers are quite rare.
This modification of heating units has good software diagnostics, so it will not be difficult for the user to understand the causes of failures and understand what to do to eliminate them.
- 1 Causes of malfunctions of Navien boilers
- 2 Self-diagnosis of Navien boilers
- 3 Error codes and how to fix them 3.1 Error 03
- 3.2 Error 02
- 3.3 Error 10
Causes of Navien boiler malfunctions
Any malfunctions of Navien boilers that are under warranty must be carried out by a service organization.
Before visiting a service organization, the consumer needs to turn on the diagnostic system, analyze the probable causes of the failure and evaluate the possibility of repair.
Error codes in Navien boilers are classified according to 3 structural elements:
- leaks in the heating circuit;
- the ignition system does not work;
- low parameters in the gas network.
Not all errors require the participation of service specialists. For example, the absence of a torch in a piezo igniter can be caused by a failure of the primary flame sensor, zero gas fuel pressure in the line, when the head valve is mistakenly closed, or in the event of a faulty ground loop.
Therefore, troubleshooting begins with inspecting the primary sensor, which must be clean and without damage. After cleaning the surface of the primary sensor, the boiler operation is checked again.
E08 – Short circuit in the DHW temperature sensor circuit
This error message occurs when the hot water sensor circuit is short-circuited or if the temperature in the DHW circuit rises above 120 degrees.
The first thing to do is measure the resistance on the DHW sensor. It should be 10.3 kOhm at a temperature of 20 degrees. and 3.5 Ohm when heated to 50 degrees. If the actual voltage deviates from the nominal voltage, then first of all you need to replace the sensor.
If the voltage is at the proper level, then you need to change the control board.
Self-diagnosis of Navien boilers
The self-diagnosis system guides the user to timely identification of faults in Navien. The electronic unit interrogates all sensors, analyzes the received data, and displays critical failures on the LCD display in the form of digital symbols. Practical guidance on troubleshooting is given in the technical documentation.
With the latest digital modifications, the monitor is located on the control panel. The codes are clearly visible even in the dark, due to the presence of bright multi-colored LED backlighting.
For different Navien boilers, information is presented in both digital and alphanumeric characters. There is absolutely no difference between failure “10” and “E10”.
E10 – malfunctions in the smoke removal system
First, we check the chimney for blockages and damage. We carefully inspect the outer part of the chimney, paying special attention to the incoming air flow grille. The latter is often clogged with debris, and in the off-season it is often covered with ice. Both dirt and ice need to be removed.
Second, we measure the output voltage on the APS sensor. If it is less than 1.7V when the fan is fully operating, then the problem is in the sensor - it needs to be replaced.
Third, we check that the APS hoses are connected correctly. The yellow hose on the sensor must always be connected to the positive (upper) sensor, and the opposite outlet of the hose must be connected to the lower outlet of the fan. Accordingly, a transparent hose attaches to the negative outlet and to the upper fan pipe.
Another possible reason for error 10 in Navien boilers is a banal excess of the smoke exhaust system. Strong gusts of wind can also be a problem.
If the above tips did not help, then diagnostics and, probably, board replacement are needed.
Error codes and how to fix them
Let's look at the most common mistakes in the video. For this, many thanks to the Repair-31 channel.
Error 03
Error 02
Error 10
Automated self-diagnosis complexes, in combination with boiler protection systems, prevent the most serious breakdowns almost at the initial stage. When detecting a particular malfunction, the program turns off the boiler and displays a code on the LCD display.
The most common failures of Navien boilers:
- E01 indicates overheating of the coolant in the boiler unit. For atmospheric ATMO models, the electric pump does not function, since in these modifications there is no heating medium flow sensor, so the pump will need to be replaced. You must first check the operation of the heating system for airiness and the presence of contamination in the filter installed in front of the boiler unit.
- E02 indicates a network water circulation error. Error 02 on the Navien boiler is eliminated by checking the circuit for leaks. The pressure in the network is set from 1 to 2 bar; if necessary, the network must be recharged. Check the operation of the shut-off valves and three-way valve; they may be blocked. Check the operation of the flow sensor. If after these procedures the problem is not resolved, the board must be replaced.
- E03 indicates the absence of an electrical signal due to the presence of a flame in the firebox or a break in the primary sensor line. In the Navien boiler, error 03 is checked in the inspection window for the actual presence of a torch. If it is not there, check the electrical resistance of the coils on the gas line cutoff. Monitor the presence of a spark on the electronic ignition system and the gas pressure in front of the boiler unit. The torch may come off due to the large volume of air supplied by the fan.
- E04, false alarm due to flame in the burner. Error 04 on the Navien boiler is possible due to a leak in the gas shut-off valve or a spark from the ignition system is supplied to the flame sensor. The electrode unit will need to be replaced. If the problem persists after this, the board will need to be replaced. You will first need to check the grounding in the boiler with a resistance limit of at least 4 ohms.
- E05, error 05 - there is a break in the return temperature sensor line or its temperature is less than 14 C. Before carrying out repairs, check the humidity at the sensor connection.
- E06, error 06 - short circuit in the return temperature sensor line or its temperature is above 120 C. Check the electrical resistance of the sensor: 20 C - 10.0 kOhm, and 50 C - 3.6 kOhm. If the value is not normal, the sensor will need to be replaced.
- E07, violation in the DHW sensor line. A similar sensor check as above is needed.
- E08, short circuit in the DHW sensor line. A similar sensor check as above is needed.
- E09, error 09 - fan malfunction. You will need to check the incoming voltage on the board in the inclusion zones of the black and red conductors. If the voltage parameters are normal, but the rotation speed is low, less than 420 rpm, it is necessary to replace the electric fan, since ignition will not occur. If the electric fan speed is 2100 rpm. and the failure is not resolved, most likely there is a short circuit in the triac line; the electronic board must be replaced.
- E010, error 10 confirms a failure in the smoke exhaust circuit due to clogged smoke exhaust channels. It is necessary to inspect and clean the chimney, and pay attention to the air intake grille to see if it is clogged with foreign substances.
E05 and E06 – open circuit of the temperature sensor, or short circuit in the circuit
We have combined these Navien boiler error codes into one section because they are very similar in terms of the conditions of occurrence. However, they require different actions. Let's figure it out.
Error E05 appears when communication between the temperature sensor and the controller is disrupted or when the coolant temperature drops below -14 degrees. There are situations when the error disappears by itself. The error message was displayed on the display for a few seconds and suddenly disappeared. This is possible if a failure occurred in the circuit, which then corrected itself. All you have to do is make sure that the connectors of the sensor and the board are dry - it is moisture ingress in most cases that leads to short-term error E05. If the connectors are dry, then it is worth replacing the sensor.
Error E06 is displayed if the coolant temperature sensor is short-circuited or if the coolant overheats above 120 degrees. The first thing to do is measure the electrical resistance on the sensor: the nominal value is 10.3 kOhm at a temperature of 20 degrees, and 3.5 kOhm if the thermometer is 50 degrees. If you deviate from the specified values, it is worth replacing the defective element - most likely, the problem lies there.
Review of less common errors
There are other less common failures that indicate malfunctions in the operation of Navien boiler units and the need for repairs:
- E011, violation of the established parameters for the level or pressure of the medium in the heating circuit. This failure appears on the LCD display of a unit with an automatic water supply system. To eliminate the breakdown, it is necessary to disconnect the heating system, diagnose the functionality of the water make-up valve, drain the residual water in the electric pump drain, reconnect it and start the boiler again.
- E012, error 12 - no flame in the boiler furnace. There can be many reasons; it is recommended to use the elimination algorithm as for errors E003-E004. First check whether the main gas valve is closed, there is voltage in the boiler supply line and whether the grounding system is reliable.
- E013, error 13 characterizes a short circuit in the line or no power supply to the heating circuit flow sensor.
- E015, error 15 - malfunction of the control board. In the event that there is no response to the supply of electricity, repair or replacement will be required.
- E016, error 16 indicates overheating of the element in the system. Any component can overheat: the electric motor of the blower fan, the heat exchanger, the electric motor of the centrifugal pump. You can independently clean the installed filter in front of the boiler, the heat exchanger and replace the thermostat.
- E017, failure caused by a DIP switch, you will need to adjust the control board options and restart the boiler.
- E027, error 27 - failure of the primary pressure sensor. Check the blockage, the smooth operation of the sensor and the blower fan. If a breakdown is detected, replace the faulty part.
- E030, excessive heating of the smoke thermostat. It is necessary to turn off the boiler unit, allow time for it to cool for at least 30 minutes, after which the unit is restarted. If the failure is not resolved, check the blower fan and the primary air pressure sensor, and clean the smoke ventilation system.
- E 093, “on/off” button is faulty It can be replaced with your own funds.
E09 – fan operation problems
When this error appears on the display of the Navien boiler, you must first measure the voltage transmitted to the fan. We measure at the connection point of the black and red wires. Ideally, the voltage should be 100-220 V.
If with error E09 the fan continues to work, but at low speed, then try replacing the fan. Most likely this is the cause of the problem.
The speed of the fan is also important. If it is within 3 sec. does not reach a speed of at least 400 rpm before ignition, then ignition will be technically impossible. If the fan speed drops below 400 rpm. during boiler operation, this will again lead to boiler error E09. However, here the electronics can handle it themselves:
- if code 09 appears directly during operation, then the built-in self-debugging system of the boiler starts;
- If the latter corrects the problem within 30 seconds, the boiler returns to normal operation.
If the fan is not active, and the board is supplied with a rotation speed of 2000 rpm, then this may indicate a short circuit in the triac circuit. In this case, you will have to change the fan.
If all the above machinations did not bring the desired effect, try changing the control board.
Tips and tricks for use
The algorithm for adjusting the heating capacity of the installation depends on the type of gas burner device. Units with electronic control - according to a given mode, the thermostat is turned on, which operates in a unit with a room temperature sensor. The adjustment is automatic; the thermometer monitors the temperature inside the room.
After it drops below the set limit, the thermostat sends a signal to start the burner device, or the regulator increases the gas flow through the valve. Usually the thermostat controls the temperature in one room, but if shut-off devices are installed in front of each heating device, the temperature will be controlled in all. The burner can be adjusted manually through the gas valve, which is especially important for atmospheric units with open fireboxes. Changing the mode is done in the menu on the control panel.
E16 - overheating
Yes, code E01 also indicates overheating, but there are slightly different causes and consequences. This error occurs if the coolant temperature exceeds a preset maximum - usually 88 or 90 degrees.
To find the cause of the 16th error, we first check the overheating and ambient temperature sensors. To understand whether they work, measuring the resistance will help - it should be 3.5 Ohms at 50 degrees and 10.3 kOhms at 20 degrees. If the ringing shows deviations, then we change the sensors.
If the problem is not with the sensors, then the thermostat could be behind the boiler shutdown and error E16. We wait until the boiler temperature drops below 83 degrees (control level) - and we will restart our boiler.
If this does not help, then we climb into the heat exchanger - for normal operation it must be clean. Therefore, we clean the exchanger - or replace it altogether.
A trivial but common cause of error E16 is the lack of water circulation in the system. Make sure the pump is working properly, the taps are open, and the filter is not clogged with dirt.
In addition, problems with the 3-way valve may cause this problem. The problem may arise if he has not moved from one position to another.
Recommended action algorithm
Check signal lines
The defect is easy to determine visually after removing the Navien boiler casing. Error 13 is caused by a short circuit, insulation melting, breakage, or unreliable contact. Inspection, troubleshooting – it won’t take much time.
Check your contacts
Before dismantling the device, you need to close the valves on the pipes connected to the Navien, drain the coolant from the boiler and disconnect the wires.
Navien boiler heating circuit flow sensor
Advice . The contact group magnet requires mechanical processing. Rinse is not enough: you need to wipe with a soft cloth until the dirt is completely removed.
If no mechanical damage is detected, perform the reverse steps (assembly). Error 13 of the Navien boiler is caused by poor preparation of the coolant and the presence of tiny suspensions in it. They are the reason for the lack of electrical contact when the sensor is triggered. After their removal, the functionality of the unit is restored.
On a note! Before starting the Navien boiler, in order to control the elimination of error 13, do not forget to bring the coolant level to normal (1.5 bar) and open the valves on the pipes. The reason that causes the 13th fault code may be the electronic board. If the error is not eliminated by the measures taken, the module is replaced - it cannot be repaired at home.
First steps
Navien boiler control panel
On a note! The manufacturer does not recommend using antifreeze in heating systems with a Navien boiler.
Check the contacts and wires for integrity of the Navien boiler
If the measures taken are unsuccessful, the reason is in the heating circuit or Navien boiler.
Air
In this case, we do not mean a plug blocking the circulation channel, but a cluster of bubbles moving through the pipes along with the coolant. A decrease in flow rate and incorrect functioning of the Navien boiler pump are not all the consequences of airing, leading to the shutdown of the unit due to error 16.
Air in the heating system
What to do . Bleed, but not at one point in the circuit, but everywhere where the corresponding fittings are installed. You should not rely on trouble-free operation of automatic valves - they sometimes fail. It is observed at facilities where owners neglect water treatment. A clogged air removal channel with dirt and weakening of the spring cause a gradual accumulation of bubbles in this area, ultimately leading to error 16. Walk through the house, check the heating of radiators and pipes by touch, manually bleed them at each point - it won’t take much time.
Checking air vents
This procedure also applies to the pump. To remove air from it, there is a washer (under the slot) on the end of the device. Place the appropriate container (bath), unscrew it 1-1.5 turns until a trickle appears and drain until only liquid flows out, without bubbles.
Filters
In addition to the main one, there is another one in Navien itself. The filter is installed at the entrance to the boiler to prevent the smallest fractions (rust, salt formations) from entering the heat exchanger from pipes and radiators. It is located in the lower part, where the unit is connected to the mains. Cleaning the mesh eliminates error 16.
Boiler pump
Problems with the pumping device also cause error 16. The pump may work, but not in the specified mode: hence the reduction in circulation speed and overheating of the Navien heat exchanger.
Check what
Check the circulation pump of the Navien boiler
Probable Causes
There may be other problems with the boiler pump. Curvature of the axis, littering of the internal air removal channel and a number of others. The shaft is not sold at retail, only order it from a familiar turner. In the second case, the pump will have to be disassembled into atoms. It will work if you want, but it’s unlikely to perform the reverse actions so that the pump works. If hidden, irreparable defects are identified, it is advisable to install a new device (a pump for a Navien boiler costs around 7,000 rubles).
Sensor
Its function in Navien is performed by a bimetallic thermostat. It rarely fails, but if you suspect that it is causing error 16, you need to check it.
Navien boiler thermostat sensor
Methodology
Three way valve
Error 16 is caused by mechanism failures. When changing the boiler mode from DHW to OV, the tap did not switch. It costs between 3,000 and 5,000 rubles (depending on the Navien model), but if you have the skills to work with a simple tool and a multimeter, it’s easy to fix the problem yourself by first removing the cover from the faucet body.
Navien boiler three-way valve leaking
Probable Causes
Boiler heat exchanger
Problems with it trigger error 16 Navien often. The device requires systematic maintenance, and if the deadlines are not met, the quality of the coolant (degree of purification, hardness index) is not taken into account when organizing the work; over time, overheating is inevitable.
What to do
Advice . When dismantling a heat exchange device, you need to lay out (on the floor, table) the removed components, parts, and fasteners in a certain order. Write down (sketch) where and which wire is disconnected. This will allow you to quickly and correctly perform the reverse steps.
Washing procedure
Flushing the main heat exchanger of a Navien boiler
On a note! After installing the unit, the coolant is added to the Navien boiler and the air is bled off. After starting the unit, there should be no error 16.
Control board
If the measures taken failed to eliminate error 16, the reason is in the electronics of the Navien boiler. The board is tightly packed, the tracks easily peel off when overheated: it is not advisable to restore functionality yourself: contact service. When called, a representative of the organization simply changes the module, and the boiler can be started.
Elements of the Navien boiler board burn out
Procedure
Reboot
First you need to restart the gas heater using the mains switch using the remote control. The South Korean company's products are resistant to unstable voltage, but if its value deviates significantly from the nominal voltage, a false fault may be displayed.
Remote control boiler Navien
If the reboot does not produce results, then the problem is in the device itself.
Checking signal lines
The malfunction is easily identified by visual inspection after removing part of the housing. Error 13 can be caused by:
Inspection and troubleshooting will take very little time.
Sensor check
To check, the sensor must be removed. Before this, you should close the taps on the supply pipelines, remove the water and disconnect the wires.
The sensor is checked in the following order:
Mechanical action is required to clean the contact block magnet. The element is wiped with a rag until the dirt disappears. If there is no damage, reassemble in the reverse order.
Error 13 is often caused by insufficient cleaning of the coolant and the presence of suspended particles. They are the culprits behind the deterioration or absence of electrical contact when the sensor is falsely triggered. After thorough cleaning, the device becomes operational again.
Before starting the boiler after eliminating the malfunction, it is necessary to bring the coolant pressure to the standard level - 1.5 bar and open the valves on the pipelines.
The cause may also be a malfunction of the electronic module. If the error is not eliminated after the measures taken, the board needs to be replaced - it cannot be restored, especially independently.
Error 13 is caused by a number of factors. When eliminating it, you should go from simple to complex, first eliminating the most likely causes.
