5 Reasons Why Your Business Needs Wall Mounted Condensing Gas Boiler？

When a customer in suburban Philadelphia called Jason Golden, owner of J. Golden Plumbing Heating Cooling in Perkiomenville, Pennsylvania, for a plumbing and heating retrofit, Golden had a solution that delighted the customer in a couple ways.

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“The customer had a 30-year-old chimney-vent gas boiler with an electric water heater serving as a hot water backup,” says Golden, who’s been in the trade for 22 years and running his own shop for five. “We were brought in to see what we could do to modernize the system. He also had an issue where his chimney was becoming old and needed some work, as well as the water heater being due for replacement. And they were also looking to free up some storage space down in the mechanical room, so we kind of killed a bunch of birds with one stone by going with a wall-hung combi-boiler. And that allowed us to eliminate extensive chimney work and the electric water heater, as well.”

The house was of older vintage, approximately 2,200-2,300 square feet in three stories, with copper tube baseboard. The homeowner was looking for energy savings, and he was also looking to free up some space in the basement that was dominated by a 3-foot x 3-foot x 3-foot behemoth of a boiler, a water heater and a tangle of pipes and wiring.

“They valued storage space,” Golden relates. “I mean, for most of our customers, storage is a premium these days. One of the benefits of installing wall-hung boilers is, obviously, we keep it up off the floor, we buy the customer more usable space in the house. It declutters things, such as low-hanging pipes and circulators because all that stuff is now moved over to the wall. We take away that 50-gallon tank water heater and replace it with the combi boiler. Plus, there’s the chimney repair that we would have to do if we kept a chimney-mounted boiler in place.”

The solution

Golden opted for a Bradford White Brute FT wall-mounted combi-boiler with a 95% AFUE. The boiler has a low pressure drop fire-tube stainless steel heat exchanger design with finned aluminum core fire tubes, sealed combustion chamber, pre-mix ceramic fiber burner and welded construction. It meets low NOx requirements at 17 ppm. It may be vented horizontally or vertically to lengths up to 100 equivalent feet. The Brute FT also features an ASME “H” stamp, 30 psi (207kPa) ASME pressure relief valve, gas leak detection, a boiler pump wired and mounted inside jacket and a built-in condensate trap and drain. It can be vented with PVC, CPVC or Polypropolene, and works with natural gas or propane configurations.

 
Space-saving advantages

Golden says the project was not hugely challenging, with the biggest issue being organizing all of the pipes, circulators and wiring from the old boiler and water heater and moving everything over to the wall. It was actually more challenging to get the old boiler, which weighed roughly 450 pounds, out of the house, he says. When customers see the difference in the space the wall-hung boiler occupies, that helps sell the job almost as much as the energy savings, Golden explains.

The jobsite was only about a half hour away from Bradford White’s headquarters in Ambler, Pennsylvania, so representatives from the factory came out and offered insights and best practices into settings and operating parameters when firing up the unit. Golden says Bradford White has been responsive, and that it’s easy to get technical support over the . Their local manufacturer’s representative in southeast Pennsylvania has an excellent track record on being responsive with repair parts and technical service. 

That kind of support from manufacturers is important to Golden because, “the customer wants to know what we can do for them and we can assure the customer that they are in good hands.” 

Installation ease

The installation time of the Brute FT is about the same as any other wall-hung boiler, Golden says. The installation is streamlined if the contractor orders the primary/secondary header that goes with the boiler. It takes more time if the wall-hung boiler is replacing a cast iron floor-mounted chimney-vented boiler because converting the piping and wiring to hang it on the wall takes longer. 

When it came to the unit’s controls system, Golden says he found it to be intuitive, and he liked its ability to be customized for each house to account for the difference between fin tube radiators and cast iron. 

The move to wall-hung condensing boilers is a slow but definite trend in his sales territory, Golden says, that will require more customer education. He installed the boiler back in January, so he doesn’t have a full year of energy bill information yet, although he expects it to be substantial. Customers increasingly are seeing the value of the energy savings they can get from high efficiency equipment, plus energy costs keep going up, he points out. Customers quickly become converts when they see the difference in the energy bills between an 80% efficient boiler and a 95% efficient condensing boiler. It makes for both happy customers and happy contractors.

Wall-hung boilers offer many options for home owners, Golden notes.

“Where they really excel is in a home with radiant heat,” he says. “That would be the biggest trend, when customers decide to go with radiant floor heat.

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We’re always trying to push them towards a wall-hung condensing boiler because that’s where they really excel. Another good application would be larger homes with multiple bathrooms or larger homes that have bathrooms with body spas or body sprays — things that use copious amounts of hot water — because wall-hung combi-boilers can generate domestic hot water for longer periods of time.”

The 5 Things You Should Know Before Buying a Mod-con, Wall Hung or Combi Condensing Boiler

• Inadequate Parts Availability

Mod-con and wall-hung boilers frequently undergo design revisions and model number and name changes. As a result, model end-of-life may occur in as little as two to three years. With so many modifications occurring, identifying and sourcing the correct repair parts may be difficult. Since supply houses sometimes stock only the current revision’s repair parts, long waits may occur even if the parts are obtainable. Also, buildings can freeze without an operable boiler, and the warranties on many mod-cons are void if restrictive antifreeze guidelines are not followed.

• Poor Boiler Design

Wall Hung and Combi condensing boilers have poorly designed critical water and air passages which easily become fouled over time reducing efficiency, requiring more maintenance, and shortening the boiler’s life. Although these tiny passages and tight tolerances may seem impressive from a manufacturing perspective, the reality is service technicians cannot access many of these passages, making service difficult and expensive. And unlike chimney vented atmospheric gas boiler designs, these types of boiler designs require routine service. The Bottom Line: Competitor design decisions to lower manufacturing costs undermines the overall quality of the boiler, compromises its long term performance, impairs the unit’s serviceability, and creates issues that are not covered under warranty.

• Built Using Inferior Materials

Critical components of mod-con, wall-hung, and combi condensing boilers are constructed using aluminum or low-grade stainless steel. These materials are not sufficiently corrosion-resistant to allow the components to deliver long-lasting condensing performance. In fact, field tests not only show this rapid pitting and corrosion, but clearly illustrate the heating unit’s degradation in its condensing performance under these conditions.

• Require Supplementary Piping and Pumps

Did you know these types of boiler designs often require supplementary piping and pumps that short circuit water flow through the system? This condition prevents condensing, wastes valuable energy, and makes the units difficult to service. These designs are so restrictive that in addition to a separate heating pump, they require a dedicated pump to flow water through the boiler itself.

• Increased Heating Bills & Wasted Energy

Temperature reset controls for these types of boilers are often permanently set at artificially high operating temperatures to avoid costly call backs for under-heating. This causes the boiler to run hotter all year round in order to quickly respond to room temperature changes. Running hotter means burning more fuel and higher heating bills. In addition, most condensing boilers have no thermal purge cycle, reducing condensing operation. The lack of a thermal plunge causes the unit to finish hot, wasting energy in the boiler and piping system.  Less condensing means condensing boilers typically miss an opportunity to flush and keep flue passes cleaner.

Avoid Condensing Boiler Issues with the Boiler That is Efficient and Built to Last

Introducing the Accel CS Condensing Boiler

To overcome the inefficiencies of these poorly designed combi boilers, Energy Kinetics created the Accel CS Condensing Boiler, the most efficient and longest lasting condensing boiler on the market. Not only is the Accel CS constructed with superior materials, it was designed by Energy Kinetics’ engineers who possess a long history of engineering excellence and leadership in the industry.

Why the Accel CS Condensing Boiler is the Informed Consumer’s Choice

1. Stronger, Thicker, and More Corrosion Resistant Materials

The Accel CS pressure vessel is made from high grade domestic stainless steel, not foreign stainless steel or aluminum. Additionally, our air and water passages are wide open, a design innovation that eliminates the need for additional energy-consuming circulators which are required on condensing boilers with small water passages.

2. Easy to Service and Lifetime Warranty

Our air passages are built with super turbulators for better efficiency and easy access for cleaning (if necessary). And our heat exchanger is backed up with a residential lifetime limited warranty.

3. High AFUE plus Thermal Purge for the Best Efficiency and Clean Operation

Accel CS’s AFUE rating is up to 97 which is the best in the industry. Although 97 is impressive, Accel CS is actually much more efficient than other systems that earn a similar high AFUE rating due to its thermal purge. The thermal purge anticipates the end of a heat call and pumps the heat remaining in the system to the top of the hot water storage tank or directly into the living space. This guarantees Accel CS runs more efficiently every cycle and condenses more to stay cleaner. In addition, it condenses more during the next cycle, delivering the best possible energy savings throughout the day and night.

Read the US Department of Energy Lab Study which shows that even our non-condensing boilers have a higher real annual efficiency than 95 AFUE modulating condensing boilers.

4. SmartBoost™ for Better Comfort and Savings

Accel CS’s performance is significantly enhanced by an outdoor temperature compensation innovation called SmartBoost. SmartBoost runs the Accel CS boiler at a lower temperature whenever possible. This greatly improves every condensing opportunity and consistently consumes less fuel. Additionally, if the boiler temperature is not sufficient to answer a thermostat call quickly, SmartBoost automatically raises the temperature of the boiler. SmartBoost is not available to other manufacturers, so their systems often run hotter all year and can’t respond to night setback thermostats, consequently wasting energy dollars.

5. Made In USA

The Accel CS is built in the US with American made quality and Energy Kinetics manufacturing excellence. From the pressure vessel to the Mil-Spec manufactured Energy Manager control, Accel CS is one of the only condensing boilers actually manufactured in the United States.

The company is the world’s best Industrial Steam Boiler supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

Accel CS = Industry’s Best Lifetime Warranty