My BIL called me over to help him fix a leaking circulator pump on his system which was an easy swap and fixed the leak. But he still has a big problem with his system, here's the current setup:
Boiler in basement Split level house with all zone loops higher than basement Three zones - all thermostats working properly Circulator pump on the cold/return side of boiler mounted just above boiler inlet comes on with furnace (zone independent) Flo-control valve on the hot/supply side of boiler mounted near ceiling Air separater right after main flo-control valve with bladder expansion tank Three additional zone circulator pumps connected to the thermostat relays Three zone flo-control valves, one right after each zone pump
The problem is that whenever any zone calls for heat there is flow thru all three zones. I verified that each of the zone pumps are working indepently and correctly. He told me that the system has always operated this way and he just sets the thermostat on the upper level to 50 so it never kicks on because he always gets heat up there. On the zone I changed the pump the flo-control valve stopped the water from coming out when I pulled the pump. I'm assuming the other two flo-control zone valves are also properly preventing back flow. But the problem is they are are always allowing hot water to flow forward even if the pump for that zone is off. There are no zone valves on any of the zones, only the flo-contral valves. The zone pumps, flo-control valves and thermostats appear to be add-ons to the original system.
Does this system need a circulator pump for each zone? Should there be zone valves installed for each zone?