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I've stumbled across a problem job with multiple circulators & multiple zones on a direct/return piping system where the common header is smaller than I'd like to see. The problem is that some pumps can't move any water when other upstream larger size pumps are operating. My question is can I resolve this problem with balancing valves on each secondary return leg, or is my only solution a reciprocating saw, and building a generously sized common header.