Trying to troubleshoot some Nest thermostats and 6 Zone Taco Box

DustyGmt

Member
Location
Vermont
New member as well as a new electrician, I finished my 4th year of electrical school a few years ago and am working on my own here and there and troubleshooting these kinds of things are not a strength. I guess ill just outline the problem as best I can.

Lady called and said she has 4 nest thermostats that arent working and the hydronic baseboard heaters arent coming on. First thing i did when I got here was pulled one of the dead nest T stats and plugged it into a micro USB to recharge it and then took a voltage reading on the Red and White wires, I was only getting 4V between the red and white at each of the 4 locations. I then went to the Taco box and tested the Line voltage and had 120v, then I tested each of the two transformers and was getting 27V, then I tested Zones 1-4 and was getting the 4V (no surprise) but Zone 6 which does the Hot Water Heater was reading out at 27V between the red and white and that is working properly. There are two transformers in this Taco Box and 2-5A Fuses and I tested those as well and they are working.

I then pulled all of the thermostats off the walls and went back to the taco box and started getting 9v on the red and white zones 1-4. I took the wires off zones 1-3 and was getting a reading of 13V on Zone 4. I apologize if this is scattershot, I'm certain my lack of experience troubleshooting Low Voltage controls is really showing here but just trying to walk you through my probably somewhat misguided process. Also turned the circuit off and put my meter on the Continuity Tone function and rang out each R/W Zones 1-6 and the only Zone having Continuity was Zone 6, the only Zone getting proper voltage and working properly.

Sorry for the giant wall of text, I'm out of my depth here and am ready to punt it to someone more qualified but its kind of eating at me that I cant figure this out, I want to become more skilled at troubleshooting these things but I'm inclined to believe that this may be a bad control box or maybe somewhere in this ugly rats nest of LowV wires there is a problem but it was working fine last winter so I'm not sure. Any tips or help from an old pro would be appreciated. Thanks. -Dusty
 
Not sure what's going on here. The terminal blocks on the bottom connect to the zone valves. 1&2 is the motor and 3&4 connects to the end switch. When the thermostat calls for heat, there should be 24VAC on 1&2. When the valve is all the way open the end switch closes "shorting" 3&4 which, through the Taco closes a relay and turns on the circulator through line voltage contacts marked "pump end switch" bottom left and also closes the low voltage contacts marked XX at the top left. XX would go to TT on the boiler which would control the circulator. Looks like this is the way it's done here.

The terminal blocks at the top connect to the thermostats. I see R&W which when "shorted" should activate that zone's zone valve as above. The "C" can be used to supply power to the thermostat instead of batteries.

Simple.

So, Check for 24VAC at the red and yellow from each of the two transformers.
Then check for 24VAC between R&C on each thermostat connector block.
If this checks out jumper R&W together on zone 1 and look for 24VAC between 1&2 on the zone 1 block at the bottom.

That should tell you if the controller is working properly. After that, expand your troubleshooting to the thermostat, thermostat wiring and zone valve wiring.

Here is a link to the Taco controller installation instructions.

https://www.tacocomfort.com/documents/FileLibrary/102-399.pdf

-Hal
 
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