The connections seem to be fine but the motor is pretty hot. I'm not sure if that is normal or not. I don't know that I have ever felt it before. Of course I guess it will run constantly (hopefully) until the temp. rises. Thats pretty hard work.
The electric circulating motor should be very warm to the touch, but not too hot to touch for 20-30 sec at a time. If it is that hot (where you will actually burn yourself touching it), then the problem it something with the pump itself, the power to the pump, or the coupling itself. It could also be the circulator itself is bad. The circulator if I am not mistaken has the output shaft in an oil bath that you can check (dipstick). Little or no oil could be the culprit. Usually when the motor is too "hot" , it is an electrical problem. But it could be the circulator "bogging down" the motor itself because of a bad bearing or coupling.
Try turning off the floor heat all together (just turn off the switch next to the flow switch on the cover on the side of the floor heat boiler). Let the system cool down for say 15 to 30 minutes. Check to see if the electric motor on the circulator cools down also. Once all is cool, turn on the system, flip the switch. If you have the temp on the aqua stat that tells the floor heat to turn on set low enough say -10 to -20 degrees, the floor heat should try to turn on. Listen for the "click" from the low water cutoff. If you hear it, the circulating motor will start to cycle. Then once the flow switch paddle senses water flow, the electric pilot will light and you should hear the boiler light.
If you turn on the floor heat and nothing happens at all, no clicking,no electric motor circulating, then you will never get the flow switch to sense the flow and the boiler will never light.
