RayV, After all of the suggestions made and what you have tried do you
have a fix? I'm curious to what fixed this problem and I'm sure the
others in the group would like to hear what the solution was.
I also posted this in alt.hvac and the predominate (reasonable) opinion
there and here is the main circulator pump on the inlet side of the
boiler is not needed in conjunction with the zone pumps. I suspect the
system would be fine with one pump and zone valves. The top floor
might not get as much flow if all 3 zones are calling at the same time
but the lower zones would eventually shut off.
This weekend I will go over and disconnect the wires to the 'main'
circulator and run each zone and see what happens. Worst that can
happen is I have to reconnect it.
If that doesn't work maybe I'll have him call in an HVAC guy for an
opinion. I could install zone valves for him and the parts would be
less than $400 (plus $30 for a bottle of vodka).
I'll post a followup after I try disconnecting the main pump.
Sounds like I misunderstood you. Are you saying that there are
circulators for each zone and then another circulator for all zones
which you call the main pump? If this is the case, then yes I agree
with you. I would disconnect the main circulator and try the heat.
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