Boiler Sizing Replacement Guide

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APPENDIX
OTHER CONSIDERATIONS IN BOILER REPLACEMENT
1. INSTALLATION INSTRUCTIONS
In order for the warranty on a new boiler to be
honored, the boiler must be installed in strict
accordance with the manufacturer’s installation
instructions. It is imperative that the heating
contractor follows the instructions furnished with
the equipment. If questions arise, the heating
contractor should contact the distributor.
2. GRAVITY SYSTEMS
Adding a circulator to a gravity system may
improve circulation in areas that had poor
circulation; however the circulator will not
increase the amount of heat available per unit of
time. The circulator should be operated with a
reverse acting control to turn it ON when system
water temperature reaches 110-120°F; OFF at
about 90-100°F.
3. STEAM HEATING SYSTEMS
Be sure to check the following:
(a) total square feet of installed radiation,
(b) modifications to the system from its original
condition,
(c) physical condition of the system,
(d) condensate return time (slow?),
(e) if the low water cuto is activated frequently
(f) if there is a pump control to operate the
condensate pump,
(g) the possibility of buried (leaking) piping.
Also, check the boiler water for contaminants by
boiling two water samples in separate pans-one
sample of tap water and one of boiler water. If
the boiler water foams over like boiled milk, the
water is contaminated and should be treated
accordingly.
4. CLEANING STEAM BOILERS
The proper cleaning of new steam boilers is
perhaps the most neglected step in steam boiler
replacement. It is also a factor many installers
overlook when estimating the cost of the job.
After installation, a steam boiler should be
cleaned and flushed. Chemical additives for
cleaning or water treatment must be carefully
considered. When in doubt, consult a reputable
water treatment firm, or Weil-McLain since most
chemicals generally cause more problems than
they solve and can void the warranty. Never use
petroleum products. In addition, a thorough
check of the valves, vents and traps should
be made to be sure they are in good working
order and are the type and size needed for the
application.
5. CLEANING HOT WATER SYSTEMS
Old hot water systems may have mud, sludge
or other accumulation which could aect the
operation of a new boiler. If there is any evidence
of deposits in the old boiler when it is removed,
the piping and radiation should be flushed with
cold water before the material hardens.
6. EXPANSION TANKS
New water boilers must be installed with a
properly sized expansion tank in order to avoid
the loss of system water during each warm-up
cycle and the replacement of the lost water with
fresh makeup water with the pressure reducing
valve. The frequent addition of makeup water to
a heating system can cause severe damage and
must be prevented.
7. THERMOSTATS
Modern controls on a new boiler will usually
require a dierent heat anticipator setting for
the thermostat. Many older thermostats either
have fixed-heat anticipators-or none at all. For
proper boiler operation and owner satisfaction,
the thermostat heat anticipator must be set
properly. Follow instructions.