Weil-McLain Boiler Keeps Running: Fix it now

 


If your Weil-McLain boiler keeps running non-stop, it’s more than just an inconvenience—it can strain your HVAC system and increase energy costs. This continuous operation can cause wear on key Weil-McLain boiler parts and may eventually lead to system failure. Identifying the cause quickly is crucial to avoiding costly repairs and ensuring your heating system runs efficiently. In this article, we’ll discuss common reasons for a running boiler and offer practical solutions to get your Weil-McLain boiler back to optimal performance.

Troubleshooting a Constantly Running Weil-McLain Boiler: Causes and Fixes

Here are the main reasons your Weil-McLain boiler might keep running, along with solutions to fix them.

1. Faulty Thermostat

The thermostat controls the room's temperature and decides when to switch on or off the boiler.If the thermostat is faulty or not properly calibrated, it may not shut off the boiler once the set temperature is attained, and this makes the boiler to run all the time.

How to Fix It:

  • Check the thermostat's settings: Make sure the temperature is set correctly.

  • Clean the thermostat: The dust and debris can block the sensor of the thermostat and cause it to read inaccurately.

  • Replace the thermostat: If it is worn out or not functioning properly, it is advisable to replace it with a new one to enhance your comfort and efficiency.The constant on/off cycle can be avoided with a smart or programmable thermostat.

2. Malfunctioning Pressure Relief Valve

The pressure relief valve helps to maintain a safe pressure in your boiler. If this valve is damaged or blocked, it leads to the system running continuously as the pressure increases beyond its control.

How to Fix It:

  • Examine the valve: There should be no cracks, rust, or any signs of leakage on the valve.

  • Replace the valve: If the valve is damaged or stuck, it will require the services of a professional HVAC technician to replace the valve to ensure the system is functioning properly.

3. Stuck Aquastat

The boiler's water temperature is managed by the aquastat. If the aquastat is faulty or stuck, the system cannot regulate the water temperature and the boiler may run longer than needed.

How to Fix It:

  • Check the aquastat: Check continuity using a multimeter.

  • Replace the aquastat: If the aquastat is not working properly, it should be replaced to ensure proper functioning and to stop the unit from running for long.

4. Air in the System

The trapped air in the boiler system hinders the normal circulation of water and thus leads to overheating and constant working as the system attempts to make up for this irregularity.

How to Fix It:

  • Bleed the radiators: This will help to eliminate any air that may have accumulated in the system and enhance circulation.

  • Check for leaks: Any indications that air may be entering the system should be looked for.

5. Incorrect Water Pressure

Boilers need water to flow at a certain pressure range for it to work effectively. If the pressure is too low, the system will continue to run to make up for the lack of flow, while high pressure will activate safety mechanisms. In both cases the boiler could be forced to run continuously.

How to Fix It:

  • Check the pressure gauge: When the system is cold, the pressure should be between 1 and 2 bars.

  • Adjust the pressure: If the pressure is low, then you can add water to the system. If it is too high, then it is possible to reduce the water level to the required value.

6. Faulty Zone Valve

In multi-zone heating systems, there are zone valves that regulate the flow of hot water to different parts of the house. If a zone valve is stuck open, the boiler will continue to run because it is supplying hot water to zones that do not require it, thus overloading the system.

How to Fix It:

  • Inspect the zone valves: Look for any malfunctions such as corrosion or wear.

  • Replace the valve if necessary: A stuck or faulty zone valve will need to be replaced to restore normal operation.

7. Clogged or Dirty Burner

A dirty or clogged burner can result in poor combustion and therefore the burner is not efficient. In this case, your boiler will keep running in an effort to meet the heating needs of the system even if it is not operating at optimum efficiency.

How to Fix It:

  • Maintain the burner: Ensure that the burner is cleaned as per the manufacturer’s instructions to ensure it works efficiently.

  • Consult a professional: If you are not sure how to clean it, an HVAC professional will help you to maintain your system.

8. Worn-Out Circulator Pump

Hot water is circulated throughout your heating system by the circulator pump. If the pump is worn out or faulty, it may lead to the system running non-stop as it tries to pump water in the system.

How to Fix It:

  • Check for any strange noises: If the pump is noisy or not working, it may be time to replace it.

  • Replace the circulator pump: A faulty pump will require replacement to ensure that water circulation and heating functionality.


To prevent unnecessary energy use and damage, it's crucial to address the cause of a constantly running Weil-McLain boiler. Your system can last longer with routine maintenance and early detection. If the issue persists, consulting a professional HVAC technician is recommended for proper diagnosis and repair, ensuring your boiler operates efficiently for years to come.


Written by Allen Rode for Partshnc, your trusted source for high-quality HVAC parts, including water heater components, air conditioner parts, and Boiler parts.

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