E04
Thermona
Overheat Thermostat Trip
Display shows E04, boiler shuts down and will not restart until reset.
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Safety Warning
This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.
If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.
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Possible Causes
Blocked primary heat exchanger in Thermona boiler, Failed or stuck pump, Closed or blocked heating circuit valves, Faulty overheat thermostat or NTC sensor
How to Fix / Troubleshooting
Safety: Allow the boiler to cool fully before touching any pipework. Overheat conditions can cause scalding.
- Check system pressure: Verify the pressure gauge on the boiler is within the recommended range (typically 1.0–1.5 bar when cold). If low, top up via the Thermona filling loop following the user manual.
- Bleed radiators: Air in the system can cause local overheating. Bleed radiators starting from the lowest floor, then recheck and adjust system pressure.
- Ensure valves are open: Confirm all isolation valves under the boiler and on the heating circuit are fully open.
- Pump operation: When there is a heat demand, place a hand on the pump body (if accessible) to feel for vibration. If the pump is silent and cold, it may be seized or not powered.
- Reset the boiler: After cooling and checks, reset the boiler. If E04 reappears quickly, the overheat thermostat or NTC sensor may be faulty or the heat exchanger may be blocked.
- Engineer tasks: A Thermona technician should check the primary heat exchanger for scale or sludge, verify pump performance, and test the overheat thermostat and flow NTC sensor with a multimeter.
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Repair Difficulty
Hard
4/5
Required Part
Primary NTC Temperature Sensor
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