water heating

Whether for a single family home, large-scale apartment complex, or commercial or industrial facility, installing a boiler system is a significant investment requiring thoughtful consideration to ensure heating comfort, reliability and efficiency for years to come. Building owners, facility managers, engineers and contractors seek systems that meet specification requirements, installation ease, serviceability, reliability, lower operating costs and higher performance. Once these major parameters are met, buyers also should consider design details that may set one boiler apart from another.

Installation Ease

The installation process can significantly impact the overall cost of any new boiler system.  Look for a boiler with design features that aid in simplifying the installation process, thus saving time and money.

An integrated control system that offers a user-friendly setup wizard with intuitive controls will simplify the boiler installation process for contractors.

Boilers with a “door-fit” design are ideal for applications that have limited access.  Not having to tear out a wall or door frame can save thousands in installation expense. Likewise, boiler room floor space is always at a premium so zero clearance boiler designs where boilers can be placed side-by-side with minimal clearance is also desired.  The key here is that the boiler still remains serviceable.

Sometimes getting a fork lift at the installation site is harder than one would think.  Smart packaging and mobile design features that mitigate this need should be a purchase target. Integrated unloading ramps that come as part of the shipping container make the unpacking process quick and easy.  Couple this feature with integrated roller casters and the boiler rolls on to the site and is easily positioned into place. If the boiler install includes a concrete pad, the shipping ramp can be used to move the boiler on to the pad as well.

For efficient operation with multiple boilers consider a control system that will fluidly connect different systems to work synchronously to ensure the highest level of performance and efficiency.

Having a correctly-leveled surface is a prerequisite to proper boiler operation and performance. Boiler designs with integrated leveling legs perfectly level the area. Simply position the boiler in place and adjust the leveling legs, which are very similar to the leveling legs on a household appliance but are industrial grade to support the weight of the boiler.

There are a variety of boiler controls on the market that offer varying setup processes and functionality, ranging from simple to complex. An integrated control system that offers a user-friendly setup wizard with intuitive controls will simplify the installation process for contractors. For example, all Weil-McLain condensing boilers, including the new Stainless Steel Vertical Firetube^™ (SVF), Evergreen^™ and SlimFit™ boilers, include this convenient setup feature in the Unity^™Controller (70-3000 MBH).

High efficiency is key when selecting boilers. Weil-McLain’s SVF Stainless Steel Vertical Firetube™ (SVF) boiler can be found listed with AHRI with industry leading thermal efficiencies up to 97.1%.

Multiple pre-set systems are another popular boiler control feature. These units feature pre-set heating systems for typical operating conditions built into the controller so installers don’t have to enter specific supply or return temperatures during installation, but rather a specific application which reduces installation costs and time while increasing reliability.

Usability

Simple, user-friendly controls also are essential for efficient boiler operation long after setup is complete. Whether managing a single boiler or a system of boilers, contractors must understand how to leverage system features to optimize performance.

In a multiple boiler system, user controls will manage multiple units to deliver the desired heat and adapt accordingly as the environment changes. For variable primary flow and hybrid boiler system applications, specifically, it is important for user controls to offer configurability between different products and technology. If one boiler in a system goes down, the unified controls will communicate across the units and vary output to adjust for the loss.

Boiler room floor space is always at a premium so zero clearance boiler designs where boilers can be placed side-by-side with minimal clearance is also desired.

With a straightforward interface and simple navigation, contractors should seek controls that provide at-a-glance boiler status, diagnostics, troubleshooting and integration with building automation systems. The right control system will fluidly connect different boilers to work synchronously and ensure the highest level of performance and efficiency.

Similarly, when expanding a boiler system, controls that maximize energy across all boilers on a system reduces energy costs. Weil-McLain’s SmartSequencing™, for example, controls an algorithm that runs as many boilers as possible at the minimum input, therefore maximizing efficiency. With this advanced control feature, boilers maintain optimal efficiency through lead-lag rotation and balanced heat loading.

Maintenance & Serviceability

Boilers must be well-maintained for their benefits to be fully optimized, and the design of a boiler can have a significant impact on its serviceability over time. Proper inspection and regular native maintenance are vital to ensure uninterrupted, reliable and safe boiler operation. Therefore, contractors will appreciate boilers designed to make annual servicing easier.

Tasks such as cleaning heat exchangers, replacing worn out components, adjusting air fuel mixture, adjusting combustion controls, and maintaining water PH balance will improve boiler efficiency and reduce costly failures, while extending the lifecycle of the unit. Easy access to boiler components will make it easier for contractors to complete these and other critical maintenance activities that support a high-performing unit.

Featuring a proprietary clover-shaped, firetube design, the Weil-McLain SVF heat exchanger provides greater surface area for maximum heat transfer.

Something as simple as selecting a boiler with a hinged cover plate can make the inspection and regular wash down process easier. In these designs, the hinged cover plate can be safely propped open like the hood of a car, granting quick access to the center of the boiler, including the burner and firetubes, for inspection or cleaning. This is especially useful in more compact boiler locations where overhead space is limited.

In addition, consider a design with a serviceable condensate tray that collects condensation during combustion. A boiler designed with a replaceable condensate tray allows for a vulnerable part of the unit to be swapped out quickly and efficiently before an expensive impact to the entire heat exchanger occurs.  This improves the longevity of the boiler and reduces maintenance costs considerably.

Efficiency

Commercial-sized boilers are rated according to thermal efficiency, which is the measurement of output heat from the boiler that is transferred into the overall heating system.  Higher efficiency boilers offer the most by reducing annual fuel consumption and capturing energy cost savings.  Reputable boiler manufacturers are rated and listed by AHRI (Air Conditioning, Heating & Refrigeration Institute), which is a North American trade association of manufacturers of air conditioning, heating, and commercial refrigeration equipment.  For example, the SVF Stainless Steel Vertical Firetube^™ family can be found listed with AHRI with industry leading thermal efficiencies up to 97.1%.

Opting for a higher-efficiency boiler will result in significant fuel savings for customers, particularly when replacing an older system with a much lower efficiency rating – such as upgrading from 80% thermal efficiency design to 95% or higher. Boilers can account for about 55 percent of annual energy bills, and building owners with high-efficiency boiler systems often report energy cost savings up to 25 percent or more on their heating expenses.  In addition, many regions offer efficiency rebates for installing high efficiency boiler systems.

With more boilers on the market offering similar functionality and performance metrics, it can be difficult to differentiate which design is the best for each application. All the particulars that impact a boiler’s installation including usability, serviceability and efficiency can set the superior unit apart from the rest of the field, showcasing a design developed specifically with contractors’ needs in mind. The smallest design details may have the greatest impact on a boiler’s value and performance over time, so choose wisely.

John Miller is the commercial boiler senior product manager with Weil-McLain, a leading North American designer and manufacturer of hydronic comfort heating systems for residential, commercial and institutional buildings.

When it comes to boiler needs and installations, no two projects are the same. The most reliable manufacturers and installation and service companies pivot based on the demands of individual projects to meet the needs of their customers. NTI has done just that throughout its over 50-year history. Each project presents individual challenges, and often the key to success is selecting the right product and having the technical expertise and the ability to communicate to clients effectively.

The Noble and Greenough School is one of those clients. It is a coeducational, nonsectarian day and five-day boarding school for grades seven through 12. It is near Boston on a 187-acre campus that borders the Charles River in Dedham, Massachusetts. Former students included former president John F. Kennedy.

Two NTI Lx-500 boilers feed four existing 200-gallon indirect water heaters.

The installation site was in the Nickerson Castle (now simply known as “The Castle”) built in 1890 for railroad tycoon Albert W. Nickerson. The Noble and Greenough School bought it in 1921 and now uses The Castle for dining services and other uses. They were having significant problems with their domestic hot water system for the rooms and kitchen, which served all 615 students. The existing boilers fell into disrepair and were having difficulty keeping up with the day-to-day school operations. Unfortunately, because the current boiler took up a small space, finding a replacement to fit the area, without requiring relocation in this historic building, was the main issue.

EMCOR Services Northeast (emcornortheast.com) is a large Boston-based mechanical service contractor that specializes in mechanical retrofit installations, HVAC maintenance and controls. They tackled the space challenge. Mark Christensen of EMCOR contacted Randy Gilman of Jomar Distributors, of Watertown, MA. Jomar reached out to NTI’s VP of Sales, Dave Walsh and Regional Manager, Ted Lowe. They recommended two NTI Lx-500 boilers because they would fit right where the original had been. The new Lx boiler would feed four existing 200-gallon indirect water heaters.

EMCOR’s experienced installation team were able to swap out the boiler utilizing the same boiler pad and had the system up and running in a matter of days while the school was shut down over the Christmas break. Both Dave Walsh and Ted Lowe worked on site with EMCOR to assure a smooth installation and commissioning. With EMCOR providing annual preventative maintenance, the boiler is expected to last significantly longer than the previous one, and with fewer issues. Mark Christensen of EMCOR stated: “I couldn’t be happier with the product and support I received from NTI.”

The take home message is that for the companies you work with, whether they are on the manufacturing side like NTI or on the installation and service side like EMCOR, the key is having knowledgeable employees and easy to work with staff. While equipment being high quality is a given, getting that equipment from people who know how to explain its operation and can work effectively with you and your team is essential.

Irvine, Calif.—Summer is the perfect time for contractors to train and educate themselves on Navien products before the busier heating season arrives. As the leader in condensing technology, Navien continues to innovate with product updates, contractor programs and new products, making Navien training essential for any contractor to stay informed on Navien and include Navien as part of their business growth plan.

Navien Training Academies offer a variety of classes covering Navien tankless water heaters, combi-boilers, boilers, accessories and more. Contractors new to Navien can attend introductory classes covering the basics of Navien products. Advanced classes detailing wiring, piping, service, hands-on training and more are offered to those with previous Navien training.

Single-day or two-day classes are offered at the state-of-the-art Navien Training Academies in California, New Jersey and Ontario, Canada. Each class at the Navien Training Academy includes a certificate of completion and a Navien parts kit of the attendee’s choosing.

For those unable to get to an Academy training, field trainings are offered throughout the US and Canada through Navien Representative facilities, at many Navien wholesale locations and specially scheduled dedicated in-field trainings.

For additional information on the Navien Training Academies, visit training.navieninc.com. For training opportunities in your area or outside of the Navien Academies, visit NavienInc.com/field-training.

Navien Training Academy Schedule – New Jersey

Navien Training Academy Schedule – California