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[Catmanwrencher]

We just recently installed a thirteen year old h4.  Prior to installation I started with all new components on the stove and completely resealed it after a thorough inspection.... With that being said all electronics are new.  My problem is since we are installed and operational now I have noticed my relay to control pump is not always latching in sometimes it will only vibrate and humm.  My first thought was faulty relay so I installed my new spare that I had on hand and still no luck... My years of field service mechanic work tell me probably not the relay!  So I used my DVOM and checked for the 24 volts ac from the transformer through the thermostat and I'm good there.  However my 24 volts pulls down to 17 volts when the relay is latched in.... So I guess my question is do I need to find a larger amperage transformer to pull the relay in?? Your thoughts on the matter would be very help full I'm getting tired of trips to hardware store and hardy dealer and Internet orders so I would like to nip this last little problem in the butt

[RSI]

How far does the thermostat wire run? If it is long, check the voltage right at the transformer when the relay is trying to pull in. If it is near 24v then your wiring is too small.
It shouldn't take much of a transformer to pull in a relay. Is it powering anything else too?

[Catmanwrencher]

I used a five wire conductor typically for HVAC use and it is all told 150 foot run from transformer to relay.  I never thought to check for the voltage at the source, I guess I should compare that to my readings at the relay to check for a voltage drop in the wire