PowerCor failures

Dave Gulbranson

I installed the original 75 gallon unit in Ocober of 2002. I installed the THIRD unit January 6 '04. The second replacement was sometime in the spring of '03. The heat source is a analog Munchkin 80m. Max ouput temp is at 170. BW recommends not going over 180. When the unit works the home owners have no complaints. Got a call Sunday from the home owner who has way more patience than I do.I can't believe how nice these people are - they have every right to be very pissed. No hot water and water leaking from the tank. I was able to reset the unit and get him going again at least temporarily.This will be the fourth indirect installed in less than 2 years! I have talked to my supplier about my options and what BW might do for me. I will not be putting in another PowerCor. Maybe an Amtrol this time? I'm using a Taco SR502 controller. I'm think the Amtroll will be compatible but I dont have any experience with them. Looks like I'll be out a day's labor and about $400 to make up the difference in cost that is if BW helps me out. Not to mention labor etc. on the other 3. We have 3 other PowerCors in the field with no problems. Oh yeah - We've been using combis since 1998, and probably have close to 50 in the field.We've replace about 8 - 10. I dont think I'll be using Them anymore. I'm scared.

Larry (from OSHA)

What are you using

for a circulator for the power cor? You've got me real concerned as I just installed a 65 gal. unit in my home. I spoke with BW about what circ to use. They said a Taco 009 is what gives the right flow. The HX supposedly has about 25 ft. of head and at 4 gal. per minute, the 009 falls in place. Do you know what exactly failed on the previous tanks? Curious, concerned minds want to know.

Thanks

Larry

Dave Gulbranson

Taco 007

We're running a 007. I know that BW wants me to use a 009 on their hx coils, but we're getting plenty hot water with the 007. To answer your other question - They're leaking out of the top. I assume it's the o ring on the coil, although I've not heard from BW on any of the others returned for warranty. You don't think the coil could be overheating from not enough flow due to a 007 with 170 degree supply temp do ya?

Larry (from OSHA)

doubt it, but

who knows. I would think that the tube could sit at 180* all day without problems. They changed the HX to PEX some time ago to deal with the problems that Hot Rod was talking about on the combi-cor thread. (Obviously they haven't fixed all the problems). I had mine running off the 007 system pump at first as well. Also had enough hot water but recovery was a little slow. I think there might be about 1 gpm with the 007, if that. My understanding is that leaks out the top is the handy leak indicator feature that code requires. Good luck and if you find out about the other ones, I'd sure like to know.

Larry

Einsiedler

bad water?

Perhaps its the water. I know that Allied Engineering (Superhot) run a higher grade steel for areas with extremely hard water. then again this "better" steel petains to the coil and not the tank itself (Not sure what exactly is leaking).

Just a thought to consider....

Einsielder

Steve Whitbeck

I have had much better luck with the superstor unit.
The Amtrol indirect water heaters use a plastic liner with a steel outer shell and I have had problems with the inner liner going bad. ( the 80 gallon and larger have a stainless tank with a plastic outer shell ) - this model is GOOD but it is comercial priced. I have used the superstor for many years and have yet to have one fail.

hr

Maybe Bradford White

will send you a PowerStor as a replacement. This has a 1-1/2" steel coil and glass lined. Go to their web page and find them under commercial equipment.

They don't qualify as a double wall HX, as the PowerCors do.

I only have a handful of PowerCors in. So far no failures. I, too, have found a 15-42 to be plenty of pump for the installations, and HW demands, I did. Certainly a lower velocity equates to less wear??

hot rod

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Mark Wolff

Same here

The 15-42 or 007 are perfectly adequate for that heater. I would hesitate to put an 009 on due to excessive wear issues too.

Also, you might want to look at softening the water (check for hardness level first) and dielectric unions at all connections to the water heater before you install the new one, or you will be back again. We have had individual houses burn up water heaters at about the same rate before, while their neighbors with identical systems are fine. Electrolosis is a funny thing.