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[yoderheating]

 A pump moving the water slowly could cause the flat plate to really pull it down before it got to the coil in the duct.

[hondaracer2oo4]

Great point Yoder.

[bajonesy77]

Just to verify your stove is 150ft outside + 75ft in home to your hx? So 225ft each way for a total of 450ft round trip? What size plate exchanger? Definitely sounds like a low flow/air lock problem.

[Wi woodburner]

I taped a thermometer to the pex at several areas inside the house.  All readings were basically the same as the Ranco temp display which is still 20 degrees cooler than the reading at the stove.  Today I am going to do this outside by the boiler to see if the heat loss is happening from the stove to the house. 

As far as air in the lines, would I be safe to open the valve and run water out the top of the vent to know it is full of water?

[ITO]

If you have a valve and vent after the pump open the valve slowly with the pump running and see if it puts any air out, you should be able to hear it purge any air if it's in the line, you will most likely hear the water fill the line as well. Just curious, where about are you in WI? I'm in NW corner of the state.

[slimjim]

Sure sounds like an airlock to me!

[yoderheating]

 Yea if you tape it to pex you will be 20 degrees off, pex just doesn't transfer heat as well as copper. After you tape it to the copper inlet of your coil you also need to insulate it.

[Scott7m]

Yea if you tape it to pex you will be 20 degrees off, pex just doesn't transfer heat as well as copper. After you tape it to the copper inlet of your coil you also need to insulate it.