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One thermostat zone is working fine, opening the zone valve and firing the boiler. The other thermostat is opening its zone valve and I can hear the relay chattering like it normally does before it fires, but the boiler does not fire. Is the zone valve bad? Does the whole valve need to be replaced or is it maybe an actuator or end switch that can be swapped out? Actually I see that the metal tab on the motor that is supposed to contact the switch is coming close but not quite reaching it. Do these valves need to be lubricated periodically or is this a bad motor?
And got the following answer:
You have a bad end switch on the zone valve. The thermostat calls for heat and send 24vac to the zone valve,motorizing the valve open and tripping the end switch.The switch turns on the boiler and the circulation pump. The easy and best thing to do is to replace the zone valve head. It depends on the brand of valve as to how you would go about this. If, i.e. Honeywell, you lock the valve open, loosen two screws, remove head and replace. A new Honeywell head costs about $60 and new zone valve costs about $100. In the mean time.............lock the valve open by hand and when the other zone calls for heat you will have heat at this zone also.................Good luck!