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7. TROUBLESHOOTING
OVERHEATING
If BoilerMate
®
overheats during space heating
months, the installation may have a problem with
the piping configuration. The water heater uses
the boiler system as its source of energy. As
such, the potential exists for the BoilerMate
®
to be
connected in a manner that forces heating water
through the exchanger even when the unit is off.
This overheating can present a scald hazard
and may damage the unit. Follow this diagram to
determine the source of an overheating condition.
PROBLEM
POSSIBLE CAUSES
SOLUTION
No hot water
1. No power to unit
2. Air in heat exchanger loop
3. Faulty circulator or zone valve
4. Faulty BoilerMate
®
thermostat
5. Boiler inoperable
1. Check circuit breaker, boiler emergency switch and boiler reset
switch.
2. Purge air. Ensure circulator is on Boiler Supply. Check air vents.
3. Check circulator and zone valve. Repair or replace if necessary.
4. Check continuity while rotating knob. Circuit should open and close.
5. Check boiler system. Boiler must operate to generate hot water.
Insufficient hot water
1. Demand exceeds capacity
2. Temperature too low
3. Boiler lacks sufficient output
4. Fouled heat exchanger
5. Insufficient heat exchanger flow
6. Loose, missing or damaged dip tube
1. Check sizing based on household size and boiler output.
2. Increase temperature setpoint.
3. Wire for domestic hot water priority. If problem persists add storage
or increase tank size.
4. Check Boiler Supply/Boiler Return during cold startup. If difference
is less than 20F, clean heat exchanger. Install water treatment equip-
ment to prevent recurrence.
5. Check for undersized or faulty circulator, stuck or undersized zone
valve. Ensure all shutoff valves are open. Check for stuck flow
check valve. Purge boiler loop to remove air.
6. Install or replace dip tube.
Water too hot
1. Temperature set too high
2. Improper plumbing
3. Temperature sensor not fully inserted
4. Stuck zone valve
5. Flow check valve stuck open
1. Reduce temperature setpoint
2. If Boiler Return is plumbed to the suction-side of a heating circulator,
overheating will occur when the home’s heat is on. Fix plumbing.
3. Fully insert temperature sensor bulb.
4. Repair or replace
5. Clean, repair or replace
Noise from BoilerMate
®
1. Air in boiler loop
2. Faulty circulator pump
3. Thermal expansion
4. Normal noise during initial fill
1. Purge boiler loop. Check air elimination equipment.
2. Repair or replace pump.
3. Ensure the proper Therm-X-Trol
®
or equivalent thermal expansion
tank is installed and the air charge is adjusted properly.
4. When first pressurized, a creaking or hissing sound is normal. After
pressurizing, the noise should stop. Always check for leaks.
Relief valve dripping or
opening
1. No thermal expansion tank
2. Thermal expansion tank set improperly
3. City pressure too high
4. System over temperature
5. Faulty relief valve
1. Install the proper Therm-X-Trol
®
or equivalent thermal expansion
tank.
2. Ensure precharge air pressure matches static water pressure.
3. Install a Pressure Reducing Valve (PRV) if city pressure is over 80psi.
4. Determine cause of over temperature condition and correct problem.
5. Replace relief valve.
Discolored water at
faucet
1. Poor water quality
2. Sediment or suspended particles
1. Have water tested for contaminants. Typical problems are:
Blue/green color = copper discoloration due to low pH
Black staining/sulfur odor = hydrogen sulfide
White deposits = hard water
Red staining = high iron levels
2. Install sediment filter, purge unit more often to avoid future problems.
Boiler will not operate
when calling for hot
water
1. Improper or loose wiring
2. Boiler high limit has been reached
3. Problem with boiler system
1. Check connections using wiring diagrams in this manual.
2. Boiler will periodically cycle on and off during operation.
3. Have boiler repaired to restore proper operation.
Circulator or zone valve
will not operate when
calling for hot water
1. Improper or loose wiring
2. Faulty circulator pump or zone valve
1. Check connections using wiring diagrams in this manual.
2. Repair or replace pump or zone valve.
