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Old 11-12-2012, 09:53 AM   #46
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put wires back where they where originally in the picture caped them off still zone 2 does not fire and circulator not running. zone 1 works still works fine. if you look in the pics you'll that pupm relay im talking about

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Old 11-12-2012, 10:09 AM   #47
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the black wire is attached to the upper terminal of the pump relay. The other end went to the circulator. The white wire that came from the circulator is nutted togehter with two other white wires one from the 120vac romex i just put there, and one goes to the transformer. I'll wait for furhter guidance from you before i go any furhter. It appears zone 2 has no power at all now
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Old 11-12-2012, 12:04 PM   #48
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You're killin' me here. lol. Ok, here goes again. Take the wire thats coming from the switch, connect the black wire to the H terminal on the 503, connect the white wire to the N terminal, right beside it. There is room for 2 wires at these locations, so now I want you to run another cable from the same terminals on the 503 to the relay on your boiler. If I remember the pics, your boiler relay has a white and black wire, wire nut the matching colours together with the wire coming from your 503. Now you should have 120 power going to the 503 and another going to the boiler from the SAME spot. Now, run cable from the relay in the 503 that says zone 1 to the zone 1 pump. Do the same with the zone 2 location and the zone 2 pump. All of these wires on the 503 should be on the same level as the 503 supply. Now, take the wire on the 503 end switch(low voltage wire, small gauge) and connect it to the terminals on the outside of your boiler(They're below where the power feeds in at the boiler, 2 small screws) If you have done this, you will have 120 feed going to 503, then to boiler, separate wires going to each pump from the 503 and low voltage wiring coming from the thermostats to the 503 and a low voltage wire from the 503 to your boiler. Now your boiler will run the way you want it to. Do not remove jumpers, there is no need.
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Old 11-12-2012, 02:44 PM   #49
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Added two more pictures #10 & #11 to the album here.

ok, All that was done just like you said word for word. The bolier works fine - all zones work independly of each other. What I was going through with beenthere was removing that old metal romex cable sticking out of the control. i just wanted to clean up the wiring - it would look more professional. There was a black and white wire still in that metal romex cable. I didn't think I needed these wires anymore, They were just hanging there going to absolutely nothing because that circulator is now wired directly to the 503, and the boiler is working fine. I thought at this point the 503 took total control of everything - so I removed them.The black wire went to the upper right side of the brown pump relay switch, I guess that's what it is - It says SPDT on it (single pull double throw) - just above the transformer if you look at the pics you'll see what I am talking about. The white wire was nutted together with the white wire coming from stairs and white wire from main power of 503. I removed that wire as well. So now the upper right connector of the relay pump switch has nothing connected to it and the white wire have been removed. Then I fired up the boiler to test it again everything work fine except zone 2 would not fire now. So I put those black and white wires that i removed back to where I found them and capped them off. Now the bolier is working correctly again all zones work independly, boiler fires, emgency switch at top of stairs works kills both zones. It makes no sense to me at all. Because those wires go nowhere and do nothing. But the boiler works - so I'm leaving it alone. It must have something to do with how this bolier was originally wired from the factory. Maybe something has to be on that upper right terminator of the pump relay switch even if it is just capped off. remember this bolier is over 20 years old - date of mfr. was 1988. To me; I,m thinking the 503 has total control now, so this pump relay switch in therory insn,t need at all at this point. Am I right here? When it comes to relay switches and transformers I really don't understand how they work. I know 120vac goes in one side of transformer and comes out 24vac to run all the appropriate switches and relays that require 24vac. I want to thank you guys for the help and patience you had with me. I could have never done this without you. Thanks. Here are some pics of the final hook-up.
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Old 11-12-2012, 04:06 PM   #50
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Glad it works the way you want now. Any frustration I had was with myself, I figured I wasn't explaining how to fix it properly and it was giving you a hassle to complete what should have been a 10 min job. I sometimes forget that not everyone who comes on here has a full understanding of the basics. This place helps me sharpen my troubleshooting skills, so its good for me too.(Looks good, by the way.)
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Last edited by Canucker; 11-12-2012 at 04:09 PM.
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Old 11-12-2012, 04:35 PM   #51
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Makes no sense. But if it only works with them connected. Then so be it.
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Old 11-12-2012, 04:42 PM   #52
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I want to thank both you guys once again for your time and patience dealing with me and my 503 switch and boiler. I could have never done this on my own at my skill level. Everything works and looks great, I didn't blow anything up, and there's heat. Thanks again.
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Old 11-12-2012, 04:51 PM   #53
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The not blowing anything up, is always a good thing. LOL.

Glad it works the way you want now.
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Old 11-12-2012, 06:26 PM   #54
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amen. thanks

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