My wife and I bought a house last year and ran the heat and noticed that the heat varied throughout the house. We have 3 zones, one basement, one first floor and one second floor. We have a Weil Mclain CGI Gold CGI-5 propane fired furnace with an 1107-1 Electronic controller. It appears that the system is only a couple of years old. Presently, we have programmable thermostats on the 1st and 2nd floors and a digital non programmable in the basement. Here is what I have for issues and I would really appreciate some help!

1- The circulator is ALWAYS on. When I saw always, I mean always, the thermostats are all Off and I have even disconnected them all - On the 1107-1 Control module, the power light and the TSTAT/CIRC light are on.

2- It appears that the valves are working fine in the basement and the 1st floor as the temperature regulates pretty well. But on the 2nd floor, its always extremely hot.

Now the questions I have -
1- Is there any way to troubleshoot the circulator and why its always on?

2- Am I wrong to guess there may be a thermostat wiring issue?

PLEASE any help would be appreciated! I will see if I can upload sopme pictures of what I have or I can email them.


Thanks

Are they honeywell zone valves or white rodgers?

This manual may answer some of your questions.

http://www.weil-mclain.com/en/multimedia-library/pdf/weil-mclain-pdf/products/boilers/gas-boilers/cgi/cgi_boiler_manual.pdf

Weather you circulator runs all the time is dependent upon how your system was originally designed and if your boiler is also used to produce domestic hot water which means it is taking place of a standard water heater.

The 2nd floor heat control situation could be as simple as a zone valve not shutting completely off or a thermostat or wiring short allowing the unit to heat all the time.
A constatnly closed end switch on the zone valve if so equipped could also explain the high temperatures.

Boilers and there control systems are usually more complex than a standard forced air heating system and most manufactures recommend they be serviced by a on site professional every year to assure there proper operation. Be prepared to study the manual above for starters and then try to obtain the brand and model numbers off any thermostat,pump (s), or zone valving so you can also obtain the information for each of those items. Anything but actual testing will be all guesswork so as I mentioned you will need to study your system,have the proper equipment to test your system and finally have the courage to dive in as they say on your journey.

Thanks for the help - They are Taco Zone valves - 571-2 is stamped on the casings.

That's the manual that I have that we found in the house after we bought it.

The boiler is used only for heat, we have a separate hot water heater.

I have whittled it down to a bad valve or bad control unit, unless anyone has other ideas..? I hate to spens $185 on a controller to find out its something less expensive or the wiring of the thermostats.

If you disconnect the wire from the upstairs thermostat that controls the valve you will soon find out if the valve is stuck open or defective. Or it might be simpler to just disconnect the wire from the valve. No matter which you choose make sure you mark down exactly what you did so you can hook it back up.