I asked for it, so here is my take on your system. Others can make any corrections they feel are appropriate. I think my calculations will be close enough for a reasonable conclusion. Two things that might make a difference would be: a) seeing your actual piping diagram because some fittings might not play a role in the calculation; and b) knowing the make and model of the circulator on the Burnham, as I assume the Burnham circulator provides adequate gpm flow and heat for your home.
Please provide the make and model of the circulator on the Burnham and if possible a piping diagram.
The ProFab website does not show an Empyre Elite 200, only a Pro Series 200, so I assume the Pro Series 200 is your boiler. The website also indicates that for the Pro Series boilers, the installer selects the circulator to use with the Optimizer (appears to be a loading unit with a Danfoss boiler return water protection valve). If I read correctly, your posts above indicate that a Taco 007 was installed with the Optimizer, and therefore that the 007 was the Empyre boiler supply circulator to the hx.
Assumptions:
1. 105,000 btuh Load (Side B) required
2.
![DeltaT ::DT ::DT](/talk/styles/default/xenforo/smileys/deltat.png)
![Fahr ::F ::F](/talk/styles/default/xenforo/smileys/f.png)
= 20 for load side (150F in and 170F out, for example)
3. Load gpm = 10.5 (20 x 500 x 10.5 = 105,000)
4. HX approach temperature: I will provide info for 10F, as that is "standard" for a plate hx, although a closer approach temperature is achievable (10F example: Side A supply = 180F, Side B output = 170F)
5. All piping/fittings are 1"
Side A (boiler to hx) pump head calculation for 10F approach temperature (10.5 gpm - see hx info below).
170' of 1" pex = 170 x 6.0 psi/100' = 10.2 psi = 23.5 feet of head
http://www.pexuniverse.com/pex-tubing-technical-specs
I'm PAUSING right here. The pump curve chart for a 007 shows practically no flow at 23.5 feet of head. And I have not yet added in the additional pump head for your fittings. In my opinion use of 1" pex for a 170' run in your situation was a serious error. (The BioHeatUSA website suggests maximum flow in 1" copper pipe at 7.1 gpm = 71,000 btuh at delta-T=20.) In my opinion the selection of a 007 in your situation also was a serious error, and I think the installer should have recognized this and advised you appropriately.
L x 7 x 2.6' = 18.2 feet equiv pipe length
Ball valve x 6 x 0.56' = 3.4 feet equiv pipe length
Check valve x 1 x 6.8' = 6.8 feet equiv pipe length
Wye strainer x 1= ???
Optimizer + Danfoss x 1 = ???
Hx 5 x 12 x 50 plate 1" ports: the GEA Flat Plate software selects a 5 x 12 x 30 plate with 1.25" ports in this application, and it shows a 1.5 psi = 3.5' head on Side A (Side A in at 180F and out at 160F at 10.5 gpm; Side B in at 150F and out at 170F at 10.5 gpm; 102,782 btuh load; 1.3 psi = 3' head on Side B; lower pressure drop/lower head is possible with more plates)
Total equiv equiv pipe length for fittings = 28.4' = 2.6 feet of head at 10.5 gpm
Side A = 3.5 feet of head at 10.5 gpm
Total pump head Side A at 10.5 gpm = 23.5 + 6.1 = 29.6 feet + ??? as above. Assume 33' total pump head.
I believe that you would need a high capacity circulator to make your system as installed work reasonably to deliver needed btu's from the Empyre, and spec'ing this is your situation is beyond any experience or competency I might have. Until this is solved, it makes little sense to deal with Side B of the hx.
Hopefully I have made mistakes which others will catch and the result will be more favorable for you.