Welcome! Here are the website rules, as well as some tips for using this forum.
Need to contact us? Visit https://heatinghelp.com/contact-us/.
Click here to Find a Contractor in your area.
If our community has helped you, please consider making a contribution to support this website. Thanks!

Energy Kinketics EKF1 Plate Heat Exchanger - Slow Leak, Can't Pinpoint Source

Options
dla06060
dla06060 Member Posts: 6
in Oil Heating

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.

IMG_1672.png
IMG_1673.png

Comments

  • Alan (California Radiant) Forbes
    Alan (California Radiant) Forbes Member Posts: 4,812
    edited June 15

    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 slab
    GGrossrick in Alaska
  • HydronicMike
    HydronicMike Member Posts: 380

    Why wouldn't you call the installer first?

  • dla06060
    dla06060 Member Posts: 6
    https://forum.heatinghelp.com/discussion/comment/1898579#Comment_1898579

    I have, I'm just curious what the issue could be.

  • dla06060
    dla06060 Member Posts: 6
    https://forum.heatinghelp.com/discussion/comment/1898574#Comment_1898574

    Thank you.

  • Robertw
    Robertw Member Posts: 89

    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

  • EBEBRATT-Ed
    EBEBRATT-Ed Member Posts: 20,545

    Unions are the most likely leak source. call the installer.

    dla06060
  • Jamie Hall
    Jamie Hall Member Posts: 27,599

    And while you are at it — make sure that the unions are as close to perfectly aligned both laterally and angularly as possible. Unions will NOT compensate for misalignment.

    Br. Jamie, osb
    Building superintendent/caretaker, 7200 sq. ft. historic house museum with dependencies in New England
    dla06060
  • HVACNUT
    HVACNUT Member Posts: 7,538

    Looks like antifreeze puddled up on the press elbow. If there is antifreeze in the system, make sure its safe for your boiler.

    PC7060dla06060
  • mattmia2
    mattmia2 Member Posts: 17,562

    clean it up and see where it starts getting wet first. probably the union because those copper unions suck

    dla06060
  • dla06060
    dla06060 Member Posts: 6
    edited June 26

    The unions were fine but the plate exchanger had developed some small leaks. It was replaced under warranty.

    Also Energy Kinetics recommends a special compound for their unions manufactured by them, not a typical pipe dope like Blue Monster.

    HVACNUT

Categories