Energy Kinketics EKF1 Plate Heat Exchanger - Slow Leak, Can't Pinpoint Source
I have an Energy Kinetics EKF1 oil boiler, installed about 18 months ago. I've noticed blue-green corrosion/staining building up on the copper pipe stubs below the plate heat exchanger (both the "Domestic Out" and "Boiler In" connections), suggesting a slow leak somewhere in that area.
I ran a flashlight/paper towel test with the boiler firing and a hot water tap open to get flow through the exchanger, wrapped paper towels around the union nuts and the 90° elbow, and let it run for ~15 min. Results were inconclusive — there's some dampness but I can't tell if it's coming from the union joints, the elbow fitting, or the plate exchanger itself weeping from the side.
A couple photos attached showing the staining pattern.
Questions:
- Any tips for better isolating which joint/component is the actual source vs. just catching drips from above?
- At 18 months, is this likely a union seal/gasket issue, or should I be thinking heat exchanger replacement already?
- Anything specific to check given it's still under warranty?
Thanks for any input.
Comments
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I'd say the HX is fine and that the unions are leaking. Isolate and drain as best as you can. Undo the unions and apply some pipe dope to the male and female faces of the ground joint and tighten. Refill and purge.
Maybe inspect the ground joint before you apply the pipe dope to see where it was leaking. Look for any imperfections that could prevent a proper seal.
8.33 lbs./gal. x 60 min./hr. x 20°ΔT = 10,000 BTU's/hour
Two btu per sq ft for degree difference for a slab1 -
Why wouldn't you call the installer first?
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I have, I'm just curious what the issue could be.
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Thank you.
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Aside from the thread seal, be sure the piping is squared up with the plate exchanger at a true 90 degrees. Those unions need to be e good and tight.
Robert W.
Energy Kinetics
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