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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. Demand exceeds capacity
2. Temperature too low
3. Boiler lacks sufficient output
4. Fouled heat exchanger
5. Insufficient heat exchanger flow
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. Air in boiler loop
2. Faulty circulator pump
3. Thermal expansion
4. Normal noise during initial fill
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. Temperature sensor unplugged
2. Temperature sensor cut or faulty
3. Water in therm-well
1. Poor water quality
2. Sediment or suspended particles
1. Improper or loose wiring
2. Boiler high limit has been reached
3. Fuse blown in Smart Control™
4. Post Purge (POS) set too high
5. Problem with boiler system
1. Improper or loose wiring
2. Pre Purge (PRE) set too high
3. Fuse blown in Smart Control™
4. Faulty circulator pump
PROBLEM
No hot water
Insufficient hot
water
Water too hot and/
or ER2 message on
Smart Control™
Noise from
BoilerMate
®
Relief valve
dripping or opening
ER1 message on
Smart Control™
Discolored water at
faucet
Boiler will not
operate when
calling for hot
water
Circulator or zone
valve will not
operate when
calling for hot
water
SOLUTION
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
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
20°F, 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.
1. If Boiler Return is plumbed to the suction-side of a heating circulator, overheat-
ing will occur when the home’s heat is on. Fix plumbing.
2. Reduce temperature setpoint
3. Re-insert thermistor wire or temperature sensor.
4. Repair or replace
5. Clean, repair or replace
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 adjusted properly
4. When first pressurized, a creaking or hissing sound is normal. After pressuriz-
ing, the noise should stop. Always check for leaks.
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
1. Sensor is unplugged from factory. Plug into Smart Control™ receptacle
2. Replace sensor wire (thermistor)
3. Replace therm-well
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
1. Check connections against wiring diagrams in this manual
2. Boiler will periodically cycle on and off during operation
3. Remove 4 screws inside the Smart Control™ wiring box. Replace glass fuse(s)
with those of the same rating
4. Post Purge shuts the boiler off prior to reaching domestic setpoint. If set too
high, the boiler may not have enough energy to raise the water temperature to
setpoint. Reduce POS or set to 0 if the problem persists
5. Have boiler diagnosed for proper operation
1. Check connections against wiring diagrams in this manual
2. PRE setting delays circulator startup. This is not normally needed in residential
applications. Reduce PRE or set to 0 if problem persists
3. Remove 4 screws inside the Smart Control™ wiring box. Replace glass fuse(s)
with those of the amp same rating
4. Repair or replace pump
13. TROUBLESHOOTING