Amtrol RTR, WH-7 Classic Series, Top Down, WH-9 Classic Series Troubleshooting, Problem Solution

13. TROUBLESHOOTING

PROBLEM				SOLUTION
	1.	No power to unit	1.		Check circuit breaker, boiler emergency switch and boiler reset switch
	2.	Air in heat exchanger loop	2.		Purge air. Ensure circulator is on Boiler Supply. Check air vents
	3.	Faulty circulator or zone valve	3.		Check circulator and zone valve. Repair or replace if necessary
No hot water	4.	Faulty BoilerMate™ thermostat	4.		Check continuity while rotating knob. Circuit should open and close.
	5.	Faulty Smart Control™	5.		If blank, check power. Check continuity across two orange and two blue leads
	6.	Boiler inoperable			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.	Demand exceeds capacity	1.		Check sizing based on household size and boiler output
	2.	Temperature too low	2.		Increase temperature setpoint
	3.	Boiler lacks sufficient output	3.		Wire for priority. If problem persists add storage or increase tank size.
Insufficient hot	4. Fouled heat exchanger		4.		Check Boiler Supply/Boiler Return during cold startup. If difference is less than
water					20°F, clean heat exchanger as outlined below. Install water treatment equipment
	5.	Insufficient heat exchanger flow			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.	Improper plumbing	1.		If Boiler Return is plumbed to the suction-side of a heating circulator, overheat-
Water too hot and/	2. Temperature set too high				ing will occur when the home’s heat is on. Fix plumbing.
			2.		Reduce temperature setpoint
or ER2 message on	3. Temperature sensor not fully inserted		3.		Re-insert thermistor wire	or temperature sensor.
Smart Control™	4.	Stuck zone valve	4.		Repair or replace
	5.	Flow check valve stuck open	5.		Clean, repair or replace
	1.	Air in boiler loop	1.		Purge boiler loop. Check air elimination equipment.
Noise from	2. Faulty circulator pump		2.		Repair or replace pump
BoilerMate®	3. Thermal expansion		3.		Ensure the proper Therm-X-Trol®or equivalent thermal expansion tank is
	4.	Normal noise during initial fill			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.	No thermal expansion tank	1.		Install the proper Therm-X-Trol®or equivalent thermal expansion tank
Relief valve	2.	Thermal expansion tank set improperly	2.		Ensure precharge air pressure matches static water pressure
	3.	City pressure too high	3.		Install a Pressure Reducing Valve (PRV) if city pressure is over 80psi
dripping or opening
	4. System over temperature		4.		Determine cause of over temperature condition and correct problem
	5.	Faulty relief valve	5.		Replace relief valve
ER1 message on	1.	Temperature sensor unplugged	1.		Sensor is unplugged from factory. Plug into Smart Control™ receptacle
	2.	Temperature sensor cut or faulty	2.		Replace sensor wire (thermistor)
Smart Control™
	3. Water in therm-well		3.		Replace therm-well
	1.	Poor water quality	1.		Have water tested for contaminants. Typical problems are:
Discolored water at					Blue/green color = copper discoloration due to low pH
					Black staining/sulfur odor = hydrogen sulfide
faucet
					White deposits = hard water
	2.	Sediment or suspended particles			Red staining = high iron levels
			2.		Install sediment filter, purge unit more often to avoid future problems
Boiler will not	1.	Improper or loose wiring	1.		Check connections against wiring diagrams in this manual
	2. Boiler high limit has been reached		2.		Boiler will periodically cycle on and off during operation
operate when	3. Fuse blown in Smart Control™		3.		Remove 4 screws inside the Smart Control™ wiring box. Replace glass fuse(s)
calling for hot	4.	Post Purge (POS) set too high	4.		with those of the same rating
water					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
	5.	Problem with boiler system			setpoint. Reduce POS or	set to 0 if the problem persists
			5.		Have boiler diagnosed for proper operation
Circulator or zone	1.	Improper or loose wiring	1.		Check connections against wiring diagrams in this manual
valve will not
	2.	Pre Purge (PRE) set too high	2.		PRE setting delays circulator startup. This is not normally needed in residential
operate when
	3. Fuse blown in Smart Control™				applications. Reduce PRE or set to 0 if problem persists
calling for hot			3.		Remove 4 screws inside the Smart Control™ wiring box. Replace glass fuse(s)
water	4.	Faulty circulator pump	4.		with those of the amp same rating
					Repair or replace pump

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