-14-
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. Faulty Smart Control
6. 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. If blank, check power. Check continuity across
two orange and two blue leads while green light
is on. If none, open control and replace fuses or
replace control.
6. 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
1. Check sizing based on household size and boiler
output
2. Increase temperature setpoint
3. Wire for 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 as outlined below. Install water
treatment equipment 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.
Water too hot
1. Improper plumbing
2. Temperature set too high
3. Temperature sensor not fully inserted
4. Stuck zone valve
5. Flow check valve stuck open
1. 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.
2. Reduce temperature setting
3. Re-insert temperature sensor
4. Repair or replace
5. Clean, repair or replace
Noise from water heater
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 thermal expansion tank is
installed and 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 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 against wiring diagrams in
this manual
2. Boiler will periodically cycle on and off during
operation
3. Have boiler diagnosed for proper operation
Circulator or zone valve will not
operate when calling for hot
water
1. Improper or loose wiring
2. Faulty circulator pump
1. Check connections against wiring diagrams in
this manual
2. Repair or replace pump
9. TROUBLESHOOTING