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Posted 27 July 2012 - 04:47 PM Weil Mclain WTGO-4 has been firing ok. It is used, at this time of year, solely for heating the domestic water in the internal tankless heater. The unit is a home heating oil fired one. Unit has a 1.25 gph 80* B Delavan nozzle. Top flue goes into a masonry chimney.The other day I noticed dark smoke from the chimney and immediately shut down the unit. Thinking soot build up, I proceeded to thoroughly clean the heat exchanger grids, box, etc. They were sooty (dry) but nothing really bad. The blower motor, air inlets, etc., were dust covered (unit is in laundry room and I have 2 teenage boys) so I dis-assembled nearly everything (pump, blower cage, couplings, housing, etc., etc. Cleaned lines, new filter, wiped everything clean and when I plugged it in (it's on a connection harness, not hard wired as of now), it popped the GFI that is on that circuit. It has however, been on a plug in since the Sandy debacle and has run without a problem.Re-set and it popped again. Plugged it directly into another GFI unit and the positive leg welded itself to the GFI contact until I yanked them apart. Really, the pos leg is now 1/8 " shorter. I'm thinking DEAD SHORT. (But where?) Beckett burner - RWB model Suntec strainer HONEYWELL ignition Unit does not have the auto purge feature of the newer ones. This one is 5+1/2 years oldI disconnected he Beckett from the wiring and tested it and it tests fine.I tested the wiring harness that I use and it tested fine.I tested the GFI and it tests fine I tested the circuit that I use and it tests fine. Nothing lights up or does anything because the GFI immediately trips.Lastly, but most important. After removing the motor leads for the Beckett, I can't recall (with absolute certainty) to what other leads they were connected. I've included a picture and would appreciate the correct wiring designations. This one was my fault and stupid! It appears as though the WHITE motor lead needs to be connected to the WHITE ignition lead.It appears as though the BLACK motor lead needs to be connected to the ORANGE/BLACK (ignition/transformer connection. I did find, underneath the service cut-off cover, a loose white wire (see picture) that appeared to be tack welded to the metal box. It looked factory ( a ground) but, could it be a loose wire that welded itself to the box and is a/the problem? It is now loose, but I will re-attach or cap it as necessary. See pictures # 4 and # 5. Should this be attached again?So, there you have it. I repaired a mechanical issue, and now have an electric/electronic problem.As these were the only 2 wires that I disconnected this should resolve this issue, but i thought that they both had 3-wire connections. My memory must not be working (shorted out?) I have included a picture of the Honeywell Aquastat #6. I have include a picture of the disconnect with the wire attached #5I have include a picture of the disconnect with the wire unattached #4I have included 3 pictures of the wire hook up for the motor ( for clarity) #s 1, 2, & 3 Below is the Photobucket link. Help pleaseMr. Lee Fix http://s1268.photobucket.com/user/Minolta101/library/Furnace?sort=3&page=1