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I'm stumped; Circulator runs continuously; Bad Powerheads?
Hot water, oil - 3 zone system, 1 circulator, taco powerheads - used for hot water in the summer.
Woke up this summer morning and heard the baseboards clicking and giving off heat. The digital thermostats were all in the off position. Found out the circulator is running continuously.
Turned off the furnace by the emergency power switch, and disconnected the #1 thermostat wires on all 3 powerheads to rule out a short or bad thermostat. Turning the furnace back on, I would hear the circulator relay click on and the circulator would run.
With all the thermostat wires still disconnected, one by one I started disconnecting the #2 & #3 wires from the powerheads and I thought I isolated it down to a single powerhead. When I disconnected this questionable powerhead and turned the power on, the circulator relay did not kick on. During this process of elimination, I made sure that I did not accidentally disconnect the transformer or circulator control wires.
What didn't make sense is the supposed bad powerhead was not in the zone that was coming on. So to double-check my work, I wired up only one powerhead one at a time. I wired up #2 and #3 to the transformer and circulator control wires. While testing, it appeared that now two powerheads are causing the circulator to run continuously. Is it possible, or could it be something else?
Testing with an ohmmeter further confused me. I thought 2-3 were supposed to show no resistance.
"Powerhead which doesn't run the circulator"
Pin 1 to 3 resistance
Pin 2 to 3 resistance
"Powerheads which do run the circulator"
Pin 1 to 3 no resistance
Pin 2 to 3 no resistance
The furnace runs fine, keeps temperature, starts and stops no problem. I've temporarily disconnected the transformer to keep the circulator from running.
Ideas? What else should I try?
PS, sorry for posting this in the wrong category...can't find a way to move it /delete/repost.