Two Intermittant Heating Problems

16 years ago

I've noticed two problems with my heating system, but not sure if they are related. Here's the background - sorry for being so long winded.

Background:

I have a Weil-Mclain Gold CGi Series 2 (which was probably installed in the 2002/2003 time frame). I have four zones:

Zone 1 - main floor

Zone 2 - upstairs (bedrooms)

Zone 3 - indirect water heater

Zone4 - radiant floor in the kitchen

I also use Honeywell programmable thermostats for zones 1 and 2, and a manual thermostat for zone 4.

At night, the temperature for zone 1 (downstairs) is programmed to drop from 66 to 62 and zone 2 is set for 66.

Problem 1:

On at least 3 or 4 occasions now in the last month, right before bed, I do a final check and have noticed zone 2 (upstairs) drop to as low as 63 (about 1 degree higher than downstairs), even though it is set for 66. My guess is that it is no longer switching on, but the downstairs heat is rising and keeping it at 63. Switching the thermostat from heat to off and then back to heat again seems to reset it and all seems to work fine for the rest of the night - with one exception...

Problem 2:

Again, not sure if this is related or not, but since my bedroom is above the furnace room, I can hear the furnace blower when it turns on, and several times now, I've heard it cycle on for about 10 or 15 seconds, then off, then on. It does this 3 or 4 times before finally cycling on and staying on for several minutes. The following morning, when zone 1 starts requesting heat, I don't notice this cycling problem anymore.

Any thoughts?

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Comments (4)

champipple
16 years ago
hi jam Â

Just a newbie here. Learning myself. But I have a single floor 2 zone system and I replaced my manual old round thermostats with Honeywell Programmable t-stats myself. If yours are anything like mine when they call for heat you should see some indication on the display that indicates they are sending a signal to the heater. Something like "HEAT ON" on the display. So if your upstairs is set for 66 and the temperature on the display shows only 63, then you should see something else on the display that indicates the tstat is calling for heat. If not it is either broken or programmed incorrectly.

But maybe I misunderstand what you are saying. If so - never mind!!!

good luck!!!
jam7340
Original Author
16 years ago
HVAC guy came out. Felt it was a sticky relay in the air handler and replaced it. Items leading to this decision were:

1. Boiler appeared to be working since other zones were not having any problems (though the occasional cycling of the boiler is still a mystery)

2. Hot water was getting to the air handler - so the pumps were working as well.

3. Air was not blowing from the handler when it should have been. Turning the stat to manual fan would begin blowing hot air, but when set to auto - sometimes would work, sometimes wouldn't

4. Turning stat off and back on would sometimes fix the problem - probably because it would reset the relay.

Regarding the boiler cycling issue - recommended a boiler cleaning and keeping an eye on it to see if the flame sensor is going bad.

My heating system is hydro-air and zones 1 and 2 are each managed by a separate air handler.
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jam7340
Original Author
16 years ago
I need to vent for a moment (no pun intended). As I researched this problem further, I've come to realize that the fan relay (RIB) in the air handler is a fairly cheap device and probably fairly easy to install. However, to fix this problem, I was charged $65 for the service call, and another $250 for the part. Is it just me, or does this sound completely unreasonable?
champipple
16 years ago
hi jam Â

Thought I posted whatÂs below a little while ago? Obviously not. Really hope now some experts jump in to answer your cost question which I just read.

Sounds like youÂre making progress. Good to hear!!!
I have a very different system (oil) but I had a sticky relay also. Was on the Honeywell control on the boiler. It would stick and if you just tapped the box it would close and the burner would come on. And sometimes it just closed by itself long after the tstat had called for heat and the relay should have been closed. Drove me nuts till I figured it out and replaced the control. I can see what your HVAC guy is saying about how resetting the tstat could reset a relay. Seems to make sense.

Know zero about gas fired boilers but on my oil fired burner (and I think on many) itÂs pretty simple to replace the flame sensor Â and theyÂre not that expensive. But I have no idea about gas fired boilers. And obviously a flame sensor that would signal a flame when one isnÂt there could be disastrous!!!

Best of luck!!