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No problem... at this point, I also feel it's a faulty aquastat... I will recheck the wiring and update the post once the technician checks it out... thanks for all your time

Hello and thanks for the information!
To clarify my issue, the upstairs zone ( connected to the RA89A ) is working fine, i.e. thermostat calls for heat, the circulator kicks in and the boiler turns...

There are no zone valves - the downstairs thermostat is connected to the Honeywell L8124aquastat and the upstairs thermostat is connected to a Honeywell RA89A relay. I did rewire the downstairs...

Well, here's a start ( sorry about the lack of camera picture quality )... picture attached is the aquastat that has the downstairs thermostat connected...

Found this on honeywell's website - the configuration I have is shown at the bottom of page 4...
http://customer.honeywell.com/techlit/pdf/PackedLit/95-6571.pdf

I kind of just noticed it recently... I checked the wiring to the aquastat - 2 wires go to the thermostat, 2 go to the 120v feed, 2 go to the boiler and 2 go to the circulator - not much to mess up -...

The cut-in is set at 160 and the cut-out is set at 180. The furnace cuts in and out at these temps... as long as the downstairs zone isn't activated... thanks

Hello,
First, a description of my system - it is a weil mclain oil / hot water furnace with 2 taco 007-BF4 circulator pumps, controlled by LUX programmable thermostats ( 2 wires connected ). The...