Energy Kinetics Overheating

Resipsa88 · April 22

Anyone know what may be causing my energy kinetics system to overheat. The dual guard has to have been reset for the past 2 nights. I have to wait for the circulator pump to cool off for the system to operate properly. It seems the circulator is overheating to me and stops operating. If I don't wait for the circulator to be cool the reset relocks out. I actually hear the water boiling and it doesn't seem the water is moving as the heat is not traveling up the main outlet branch.

the circulator pump was replaced 2 years ago with a standard 007 after the 007e failed.

obviously I should get a tech but outside of the circulator pump potentially failing again or getting jammed any suggestions. I guess the other theory is airbinding at the circulator but seems odd once it cools that the circulator would be able to unbind.

Or the temperature sensor maybe on the kinetics in the boiler is not registering properly. I did notice the sensor on the control seemed to be out of line with the manual temperature.

szwedj · April 22

@Resipsa88 The fact that you have to manually reset the Dualgard, means your system is hitting the manual reset high limit temp of 250F. The only time we usually see this happen is when the system circulator totally stops working and there is no flow of water inside the vessel. The fact that the temperatures don't exactly line up between the System Manager and the Dualgard is pretty normal, the Dualgard's sensor is in the boilers supply piping and the Manager's sensor is located in the boiler's return. While two years is not typical, I think its very likely your service tech will find that your 007 system circ needs to be replaced again.

Resipsa88 · April 22

@szwedj Thanks. My gut was telling me it's my circulator being on its last leg. Sort of crazy that my circulator pumps are lasting only 2-3 years. the 007e had a circuit board failure, and this one seems to be having a motor failure. I am tempted to swap to a grundfos since those circulators seem to be holding up better in my system.

Maybe ill swap it to the grundfos Alpha that I was thinking of swapping it before I went the 007 and use the 007 as a backup if I need and rebuild the cartridge.

szwedj · April 22

@Resipsa88 Understood, normally the 007's are pretty bulletproof, but if you go Grundfos, either the 15-58 or the Alpha will work. Swapping out the cartridge would be the fastest and easiest way to stay up and running.

Jamie Hall · April 22

Two years for a pump does seem a bit short… but, if one was a board and one a motor, I'd run over the electrical connections supplying power with a fine tooth comb. Nothing like a slightly bad connection somewhere to take down electrics.

pecmsg · April 22

That's the problem with ECM motors, the money you save gets paid back with early failures.

Stick with the old tried and true 007.

Resipsa88 · April 22

Appreciate all the input. I did have an electrical outage a few weeks ago, wonder if it messed up the motor. I was worried it would have messed up the digital controller, but seemed to act normal.

Resipsa88 · April 22

https://forum.heatinghelp.com/discussion/comment/1894880#Comment_1894880

The first one was a the controller faulting non electrical. The second one is definitely the motor overheating. I Am going to swap it and if it fails after a short period I will go over it. I did run a test after the first ones controller failed and at that time the electric was operating normally

Dave H_2 · April 24

2 failures in two years, i would start looking at a couple of things;

system pressure, ensure that you are at least at 12 psi and check the expansion tank (remove the water pressure from the tank, then check the air pressure) You said it sounded like kettling in the boiler, a proper high pressure will prevent that from occurring.
Water quality has alot to do with circulators failing prematurely. The dirtier the water, the less flowrate can occur as passages get clogged even circ cast iron volutes get clogged. Magnetic dirt separators and chemical cleaning and protection goes a real long way.

Circulators don't have "last legs", they either work or don't work. There is nothing to wear out to make it performance drop.

pedmec · April 24

Definition of insanity is doing the same thing over and over again expecting a different outcome.

A 007 wet rotor is a pretty good circulator and american made. They don't normally fail after 2 years. i would pay attention to your system to see what's happening. I'm pretty sure this is one of those situations where the circulator is paying the price for a fault in the system.

pecmsg · April 25

Post a picture of this circulator and another of the boiler piping.

Resipsa88 · April 26

https://forum.heatinghelp.com/discussion/comment/1895013#Comment_1895013

No I understand. I actually designed water pump impellers in undergrad. The thing is it only happens after several hours of running and the pump housing becomes insanely hot. After it cools, it will work like brand new. The Expansion tank actually was my first thought but the classic tap on it test says its pressurized, and the pressure reading gauge appeared to show it has air pressure. The first Taco 007e had a software error the plug failed to maintain contact with the power.

I mean the other thought is it becomes air bound after all day running, but that seems unlikely to me. As it would be more likely the air would get trapped after it moved into my first floor radiator.

EBEBRATT-Ed · April 26

If the circ is that hot it is probably not moving water. You can't guess. You need a pressure gauge on the system you can trust. You can put one on a drain valve. Need to isolate the EX-tank and check the air pressure. Put an amprobe on the pump to see if it is pumping

pedmec · April 27

If what you say is true that the dualgard is shutdown the boiler at 250 then the boiler water temperature is ruining the 007. The 007 are only rated for 230 degrees and the dualgard is tripping at 250.

Resipsa88 · April 27

https://forum.heatinghelp.com/discussion/comment/1895226#Comment_1895226

I believe the Dualguard is set lower on a EK system than 250. But I would agree, however I believe the circulator not moving the water is what is causing the temperature to get like that. However, it hasn't happened the past 2 days. Of course it also was warm and barely ran the boiler the past two days (a little at night).

HVACNUT · April 27

What condition is the air eliminator in? What position is the bypass valve in? It should be about half way as shown in the schematic. Never closed. Is there a plate heat exchanger for a water heater, or is it just a bypass?

Screenshot_20260427_191127_Samsung Notes.jpg

Its odd there's reoccurring circulator issues.

@Resipsa88 , you mentioned ratiator. What type? Is it a monoflo system? How many zones?

pedmec · April 28

It is mostly set lower but it cannot be reading an accurate temperature. Your resetting the high limit which means where ever that dualgard is measuring its not accurate. But this issue is you lost (2) circulators.

Energy Kinetics Overheating

Comments

Categories