Taco 572 Heat Motor Zone Valve offers a convenient way to create individual zones in radiant heating or hydronic heating system. Using a single circulator pump with multiple zone valves makes it possible to start/stop the flow and divert it to achieve individual room or area comfort control and energy savings. Taco Zone Valves are the the industry standard for heating applications. The manual open lever and twist off head makes installation and service easy.
Features:
| Application: | Zoning |
|---|---|
| Size: | 1" |
| Position: | Normally Closed |
| Flow Capacity (Cv): | 7 |
| Max Flow (GPM): | 10 |
| Min Flow (GPM): | 6 |
| Flow Range (GPM): | 6 to 10 GPM |
| Width (Inches): | 3-5/8" |
| Body Pattern: | 2-Way |
| Height: | 4-13/16" |
| Connection Type: | Sweat |
| Material: | Bronze |
| Voltage: | 24V |
| End Switch: | Yes |
| Amperage: | 0.9 |
| Depth (Inches): | 2" |
| Max Pressure (PSI): | 125 |
| Wiring: | 3 Wire Terminal Block |
| Hertz: | 60 |
| Max Temp (F): | 240°F |
| Temperature Range (F): | 40°F - 240°F |
| Min Temp (F): | 40°F |

It sounds like the valve is bad. If that is the case, you will need to replace the whole unit.
Please refer to page 4 of the following product data file: http://s3.pexsupply.com/manuals/1296583564519/45982_PROD_FILE.pdf
They should only be in the open position when there is a call for heat.
Yes, they do. The part number is 555-050RP.
You need one zone valve in each zone.
You can take a look at this wiring diagram: http://www.taco-hvac.com/uploads/FileLibrary/100-3.pdf
It seems that you would need a Zone Valve Power Head (Series 570) SKU: 555-050RP.
Yes, you would be able to wire the zone valves before you install them into the system to ensure they are operating properly. However, there should be no factory smoke coming out of the unit. We recommend having a licensed installer come in and double check the wiring.