What might go wrong? Callbacks are extremely costly.
It was not a complex project: changing the old cast iron boiler with a new condensing boiler. You cracked it in a few days. Thereafter, an array of callbacks from the client started. We've all had tasks that haunted us and cost us money. Here are some strategies you can use to limit such instances.
Venting
The new condensing boiler normally vents through the house's sidewall. All you have to do is to drill two 3-inch holes and you're set. This is one of the most important aspects of the project and must not be disregarded.
As you consider how to build a boiler that vents horizontally through the wall using PVC (“Pipe Very Carefully”) strategy. The “Pipe Very Carefully” analogy typically applies when it comes to older homes. Besides, the following are rules for horizontal terminations as published in section 804 of the International Fuel Gas Code:
- The termination of mechanical draft systems adjacent to walkways shall not be less than 7 feet above the level of the walkway;
- The vent system must end at least 3 feet above any forced air entry within a 10-foot radius.
- The vent system must end 4 feet horizontally from, 4 feet below, or 1 foot above any window, door, or gravity inlet into the site.
- The vent termination must be at least 3 feet away from an interior corner formed by two walls that are perpendicular to each other.
- The vent termination must not be installed directly above or within 3 feet horizontally of an oil tank vent or a gas meter; and
- The vent termination's bottom must be no less than 12 inches above the completed grade.
Precisely, it is time to properly vent the new boiler. However, anything directly below the vent termination is not covered by the code: suppose you have a particular shrub or garden that you adore then, the acids from condensing flue gases will kill anything near the termination point.
Orphan
Another aspect to consider when sidewall venting a new boiler is what to do with the water heater vent which is referred to as an orphan. If you overlook the abandoned water heater, you will almost certainly receive a call at some point in the future, and it may be a costly one because the chimney is significantly larger than required size for one water heater. Besides, the flue gases for the water heater will condense if an old water heater flue is left in the chimney. At this point, you should apply ‘The Seven Times Rule’. Simply, the common flue cannot be greater than seven times the smallest flue.
The present chimney, for example, is 12 inches by 12 inches, giving it a total interior area of 144 inches. The water heater's existing flue is 4 inches long. A 4-inch flue has a surface area of 12.56 inches. The greatest area you can use is 87.92 inches when you multiply 12.56 by 7. This is significantly below the present chimney's 144-inch area.
In such instances, a chimney liner or sidewall venting would be required for the water heater. Suppose you are unsure of how you'll compete with the lowest bidder on this project, then making copies of the International Fuel Gas Code and showing it to the consumer is a good idea.
Maintenance
Whenever I tell homeowners to replace their old boiler with a new condensing boiler, I always emphasize that the new boiler will require more maintenance than the old one. Most of the homeowners rarely do proper maintenance on the old boiler type with the standing pilot light. The boiler is only checked by a service expert when it has broken down or stopped working.
One of the most common concerns I get from customers is that they were unaware of the new boiler's maintenance requirements. It's something I utilize as a selling point by making a customer comprehend.
We roughly have 4,000 heating hours per year on average in my area. When addressing boiler maintenance, I prefer to use a vehicle metaphor. I have the customer visualize their car operating at a constant speed of 25 miles per hour for 4,000 hours. The vehicle would have traveled around 100,000 miles at the conclusion of the 4,000 hours. At the very least, the owner would have 33 oil changes, four new tires, and new brakes throughout that time.
When I compare it to the time it takes to perform boiler maintenance, the boiler appears to be a bargain. Because the other person will not even mention it, you may include maintenance in your pricing.
Parts are available.
We recently replaced a 30-year-old boiler with a new condensing boiler. According to the salesperson, this was a brand-new boiler and it was fantastic. The salesperson did not reveal that they did not have many boiler components in stock.
The improved radiant heating system and lower fuel expenses were a big hit with the owner. For nearly two months, the system worked perfectly. The owner called on a particularly frigid Friday to say the boiler had broken down. The issue was determined to be a faulty inducer motor by our specialist.
I hope this saves you time and money on your next condensing boiler project.