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Boiler Was Plumbed Wrong...
I just purchased a 10 year old home and after we moved in I realized that the original boiler had been plumbed completely wrong. I've attached a diagram of how it is currently laid out. There are only three zones, one is a slab (1st floor) the other two are stapled under the 2nd story subfloor (bedrooms and living space). As you can see the mix valve is useless installed the way it is and also the boiler setpoint is 140F with the return water temp well under the 130F recommended for a cast iron Gold CGs. Also, the circulation pump installed on the secondary loop is ALWAYS on; if the boiler has power to it the pump is running, even if there is no demand for heat and all the zone valves are closed! I can't believe that this thing has been setup this way for 10 years and I'm just not sure the best way to go from here. I'm in Durango, CO where it's DRY so hopefully condensation will not be as big of an issue but I'm not holding my breath for the boiler lasting me for another 10 years. Any pointers on how to make this thing right other than completely tearing it all out and starting over? I'm perfectly comfortable with doing the required mods and wiring and would love your input.