Ray Wohlfarth

Always assume the old boiler was installed wrong. This principle has served me well in my career by finding problems before we own the system.

"According to the ASHRAE HVAC Applications Handbook, the estimated life of an air-to-air heat pump or a rooftop unit is 15 years while a boiler life expectancy is between 24-35 years, depending on the boiler type. So, you will install two heat pumps or rooftop units for every boiler. Where do you think those old units will end up?" I ask the class.

The students in the dormitory started complaining of headaches and nausea. When the number of students with the same symptoms kept rising, the administration knew something was wrong. The maintenance department dispatched a service technician to investigate.

On the older hydronic systems, replacing the existing boiler with a new one was pretty straightforward. The installer connected the new boiler to the existing flue, piping and electric. The newer high-efficiency boilers are much different and require some additional planning.

Troubleshooting hydronic systems can be challenging, as the pipes are hidden behind walls. Your imagination has to help you “see” the routing of the piping. 

An electrician walked into the equipment room to diagnose and repair an electrical problem in the school. 

It was such a simple project; replace the old cast iron boiler with a new condensing boiler. You knocked it out in a few days. 

When troubleshooting a hydronic system, the piping layout is often confusing. To understand the system, I sometimes sketch the piping to help me visualize the flow of water.