Product Innovations

Our survey also asked manufacturers to tell us about their latest product innovations:

“The demand for boiler solutions that support building decarbonization and electrification has not gone unnoticed. AERCO recently launched several solutions to address that demand.

“The Benchmark E is our new electric boiler for commercial applications marked by the same reliability and performance that our customers know from our gas-fired Benchmark boilers. We’ve also integrated many controls to fully capitalize on the benefits that electric boilers bring, such as peak load management and hybrid gas/electric boiler plant management. 

“We’ve also introduced a new immersed electrode boiler, the Sequoia. It is an electric solution for large industrial applications, such as manufacturing plants looking to significantly reduce their carbon footprint in the production process.

“CFR is a high-efficiency boiler that is safe to use with existing Cat I/Type B venting while delivering thermal efficiency of up to 87.6 percent — the highest in its category. Many building owners want to install boilers with higher efficiency, but cost and building infrastructure can be prohibiting factors. CFR is an excellent option in such applications.”

— Christian Zapata, product manager, AERCO

“Our product portfolio includes models with built-in Wi-Fi modules to enable a homeowner or service person to connect to it via an app. We have products with a combustion management system to ensure optimal performance without the installer needing to make manual adjustments. We have also introduced more simple things, such as adding handles to our heat pump water heater to make the work of an installer a little bit easier.”

— Dan Moffroid, director of product management, Bosch Home Comfort

“Flexibility at installation and enhanced performance for the end-user are key innovations in the latest Bradford White product offerings. The Brute FT Series 399 boiler, for example, is available as a wall-hung unit or can easily be placed on the floor via a floor stand kit. It includes top and bottom water and gas connections and the controls can manage four pumps — boiler, domestic hot water and two zone pumps with individual temperature control for jobsite installation flexibility. 

“We added domestic hot water Smart Priority technology to the Brute FT Series boiler platform. This technology evaluates operating conditions and allows for simultaneous domestic water and space heating production when the domestic water does not need the full input of the boiler. Traditional control strategies stop space heating while the domestic water demand is satisfied, rather than continuously heating the living space like the FT Series does.”

— Jim French vice president of sales, boilers and specialty products, Bradford White Corp.

“We continue to expand our onboard Wi-Fi, HTP Link, as standard equipment for many of our products. HTP Link allows the contractor and homeowner to connect the boiler to our platform. This gives the contractor the power to monitor, adjust and troubleshoot the boiler without having to go to the jobsite. 

“HTP Link will also send push notifications to alert customers when it’s time for service or there is a problem. Often the contractor will know about a problem before the homeowner does. HTP Link is available on our ELU and EFTU models. 

“All contractors have expressed a need for a wall-hung boiler with a higher BTU range. This year, we launched our new EFW Boiler, a wall-hung, fire-tube boiler that incorporates stainless-steel piping with both top and bottom connections. The EFW is available in 285, 340 at 399,000 BTU.”

— David Walsh, director of business development, HTP

“IBC’s latest innovation is the new Sky35 Controller, designed to optimize the operation of hybrid heating systems using multiple heat sources. It puts years of hydronics experience into the hands of a contractor, eliminating much of the guess work involved in integrating and managing multiple heat sources — including gas boilers, electric boilers and air-to-water heat pumps. It also helps reduce energy costs for the homeowner.

“IBC is the first boiler manufacturer to introduce an award-winning (Good Design Award from the Chicago Museum of Architecture and Design) wireless cascade function in our SUPERFLOW line of boilers, combi and tankless water heaters. It not only eliminates the typical wiring between units, saving installation time and material costs, but also provides greater redundancy since each unit in the system has a direct wireless connection to the leader.” 

— Mike Senk, product specialist, IBC Technologies

“The Laars FT Series 399 boiler is available as a wall-hung unit or can easily be placed on the floor via a floor stand kit, and includes top and bottom water and gas connections. The controls can manage four pumps: boiler, domestic hot water and two zone pumps with individual temperature control for jobsite installation flexibility. 

“Laars has also added domestic hot water Smart Priority technology to the FT Series boiler platform. This technology evaluates operating conditions and allows for simultaneous domestic water and space heating production when the domestic water does not need the full input of the boiler.”

— Chuck O’Donnell, director of marketing, Laars Heating Systems

“Lochinvar is an innovator in designing smart controls that dramatically reduce emissions. These controls use real-time data to boost efficiency as high as 99 percent. Gas units with smart controls can modulate with precision, eliminating wasteful short-cycling. Lochinvar’s CREST boiler with Hellcat combustion technology uses RealTime O2 Trim combined with Smart Touch control to instantly adapt to its environment, including altitude, and adjust to accommodate peak demand. 

“To support the decarbonization transition period, we’re also advancing our fire-tube boiler technology. Lochinvar’s FTXL boilers deliver 98.3 percent thermal efficiency and up to a 10:1 turndown ratio. The stainless-steel fire-tube heat exchanger allows the units to operate over a wide range of flow rates with minimal low-pressure drops, making them more flexible at handling frequent fluctuations.”

— Ross Brawner, product manager, Lochinvar

“Navien has always built boilers focused on easier installations and matching the performance to the system requirements. For example, the latest boiler Navien released is the NHB-H, which is an update to the NHB. The boiler retains the highest turn down ratio at 15:1 as the previous version, along with increased venting capability, and four sizes from 55 MBTUH to 150 MBTUH in a compact cabinet. 

“The updates to the new product include a multiline display with clear text for settings or control features, built-in zone control for up to three zones of pumps or zone valves, a built-in setup wizard to help the contractor during installation, and a new stainless-steel boiler manifold to improve near-boiler piping and reduce installation time.”

— David Hoskyn, director of product management, Navien

“NextGen Boiler is the first to develop the plug-and-play modulating electric boiler. Our compact modulating boiler has met market demands for the consumer while being a favorite for contractors to install.”

— Todd Seed, partner, NextGen Boiler

“Rinnai has been at the forefront of innovation and recently launched several new products featuring the Smart Sense gas-adaptive valve and Smart Connect Bluetooth-enabled Quick Setup. The Smart Sense gas-adaptive technology greatly simplifies the installation process, eliminating the need for an orifice change based on gas type. It also monitors gas heating values and optimizes combustion to improve overall combustion efficiency, driving incremental savings. 

“The Rinnai Central App gives homeowners and contractors the ability to remotely access data, change temperature setpoints, retrieve history of equipment failures and receive alarm notifications. Rinnai Central leverages the Pro-Login credential, helping contractors install, service and troubleshoot the unit; access documentation; order parts online; register newly installed products; and contact Rinnai tech support. 

— John Kopf, senior product manager, Rinnai

“On the condensing side of the business, we incorporated mobile device support to maximize the user experience with our USB Connect. Our water and steam boiler products are some of the most efficient in their class, and as we look at decarbonization and electrification initiatives in the industry, we focused on releasing two new products: the Ambient Electric Boiler Series and the Ambient Air-to-Water Heat Pump Series.

— Chris Decato, product manager, U.S. Boiler Co.

“A key trend in split-system air-to-water heat pump capabilities, coupled with market incentives, has led to a convergence of heat pumps and boilers to provide the next generation of home comfort. Heat pump capabilities continue to expand, enabling proliferation in colder climates where gas boilers are installed. 

“Furthermore, a major trend is pursuing the opportunity of optimizing grid interactivity (utility coverage/load flexibility) for homeowners and providers alike by enabling dual-fuel capabilities within the end-use appliances. Weil-McLain is developing a hybrid dual-fuel line to meet these market needs. 

“Lastly, the skilled labor shortage will continue to be an industry headwind. Therefore, Weil-McLain is innovating products and training/education methods throughout the lifecycle (ease-of-installation, service and replacement) to address this challenge.”

— David DeVries, director of product management, Weil-McLain

Listening to the Customer

“There is an endless amount of customer feedback we obtain over the years from conducting user experience tests and simply asking questions,” notes Dan Moffroid, director of product management, Bosch Home Comfort.

Joe Langlois, executive director of engineering and marketing, ECR International, couldn’t agree more: “All our new product designs go through a process whereby we collect and analyze customer feedback. This is an important part of the development process. Our installing contractors provide us with the best hands-on, real-world information that we use to make our products better.”

In fact, all our manufacturers couldn’t agree more. Our report’s most unsurprising conclusion is that manufacturers say they’ve learned a thing or two by paying attention to what their customers say.

“Lochinvar has always considered the voice of the customer to be one of the highest considerations when developing new products,” says Ross Brawner, product manager, Lochinvar.

Brawner adds that Lochinvar’s training programs — on-campus, in the field or its traveling Mobile Product Showcase — all include dedicated time to discuss the needs and wants of contractors, engineers and distributors.

“Through these conversations, we know customers nationwide are expressing great interest in electrification and decarbonization,” he notes. “Lochinvar has a long history of innovation and we’re focused on developing electric, high-efficiency and heat pump water heating technologies to ensure that we offer gas and electric solutions to meet a variety of needs.”

In fact, this voice of the customer helped AERCO develop its CFR boiler as result of a very specific piece of customer feedback concerning a potential project on the West Coast.

“It was a historical building and changing the vents to enable condensing boilers to be installed was not possible,” explains Christian Zapata, product manager, AERCO, “and they had to go with a less efficient, noncondensing solution.”

This and other feedback prompted the company to develop a Category I boiler that “could be the perfect drop-in in these cases while staying true to AERCO’s commitment to deliver boiler solutions marked by greater energy efficiency, reliability and lower cost of ownership,” Zapata adds.

Customer feedback also helped David Walsh, director of business development, HTP, develop a new product.

“Our engineers and marketing people spend time in the field learning what the contractor truly needs in a product to fit the applications and the installation needs they have,” he says.

Walsh regularly gathers user panels comprised of contractors and engineers who use HTP products as well as competitors’ products.

“They openly share with us what they would like to see in a product,” he explains. “It is this direct field input that allows us to try to put the right product in the market. This is evident with our most recent product, the EFW. Our customers came to us and asked us for a product with higher inputs and installation flexibility. The EFW delivers this by bringing the range up to 399,000 BTU, top and bottom connections and flexible venting options.”

In addition, contractors want products for residential applications designed for confined spaces in retrofits and new buildings “where space is at a premium,” says David DeVries, director of product management, Weil-McLain.

“Weil-McLain’s ECO Tec combi boilers were developed as a direct result,” he explains.

The ECO Tec “combines the warmth of high-efficiency space heating,” DeVries adds, “with the convenience of on-demand domestic hot water in a compact, space-saving, easy-to-install package.”

This premium 95 percent AFUE unit is available in three combi sizes — 110, 150 and 199 MBH input — and provides up to an impressive 5.4 gallons/minute.

“The boiler was designed with direct feedback from contractors before and during the development phase,” DeVries says. “We strategically positioned critical parts for fast and easy access.” The Unity 2.0 touchscreen boiler control connects to the ProTools App via Bluetooth. Technicians can view operational logs that provide trending data for monitoring system performance and detailed information for potential fault conditions. All-Important Feedback There’s simply no way to release new products or, for that matter, improve existing products without customer feedback, notes Dan Rettig, product manager, Thermal Solutions.

“We listen to specifying engineers, installing contractors and facility owners/operators to make sure the products we offer are truly needed for most of their applications,” he explains. “If manufacturers are not careful, new products can become burdened with excess, unneeded features driving up price to the end-user.”

In other words, give the customers what they want in order to make their work a snap. And what else are they asking for?

“We have incorporated new digital tools for troubleshooting and servicing that allow the installing contractor to interface with our boilers,” Langlois says.

Daniel Torres, regional product director, NTI, adds: “We have new user interfaces to be released soon that will make it easier for contractors to install and troubleshoot our products. And connected products through Wi-Fi help support our customers with remote diagnosing.”

Easy Work

“We continue to improve our boiler controls because our customers appreciate the value they bring,” Zapata says. “Our boilers are easy and intuitive to operate with the controls, while enhancing boiler plant performance.”

For example, he notes that the newly launched Benchmark E and the aforementioned CFR are both designed with the AERCO Edge Controller.

“It enables different products to be paired and operated together,” Zapata explains. “Both can be easily paired with our SmartPlate EV indirect water heater for a combination plant. Benchmark E can be sequenced with the gas-fired Benchmarks for a hybrid boiler plant.”

Jim French, vice president of sales, boilers and specialty products, Bradford White Corp., adds yet one other element centered on greener boilers.

“As the market continues to move away from noncondensing to condensing products,” he says, “most manufacturers of condensing products only offer wall-hung condensing boiler products.”

That concept was a major influence on its latest residential condensing boiler design.

“The Bradford White Brute FT Series floor-standing combi boiler includes contractor-friendly elements to speed up installation, such as a built-in low loss header, 3-in-1 assembles (includes pressure relief valves, air eliminators and low water cut-off), thermostatic mixing valve, heating loop pump and multiple venting options,” French adds.

The controls also include quick set-up control functions and high and low temperature heating demand control for multiple zones.

“By adding such features, many near-boiler piping activities can be eliminated,” French explains, “greatly reducing installation time so a contractor can be more efficient and move on to the next job.”

French’s corporate colleague, Chuck O’Donnell, director of marketing, Laars Heating Systems, told us something similar about the time-saving features of his company’s FT Series floor-standing combi boiler.

David Hoskyn, director of product management, Navien, adds: “Most of the new features are based on comments or requests from the field, such as the set-up wizard on the boilers.”

The biggest trend he’s seen are improvements to the boiler controls and user interface. 

“As boilers become more advanced,” Hoskyn adds, “it is important to make it easier for the contractor to navigate all the features during installation or service.”

With the number of settings or parameters available on boilers now, he notes that helping contractors ensure they start the boiler properly reduces installation time and potential callbacks.

“Building the zone controls into the boiler also reduces additional components that may be needed on a job,” Hoskyn says. “And since contractors often deal with multiple products, having expanded text capabilities on screen to describe settings can help someone quickly understand without referring to a manual.”

Simplicity is what contractors have been looking for in their products for years, says Mike Senk, product specialist IBC Technologies USA.

“So, we have aimed to produce products that are easier to use, with more intuitive controls and fewer parts,” he explains. “IBC aims to design products that not only have fewer parts, but also more universal parts. This helps the environment with less wastage, helps reduce inventory costs for contractors and reduces the number of SKUs for distributors.” Customization On a related customer-service note, we asked:

• Are you able to customize boilers to meet specific requirements or specifications? If so, what is the process for requesting customization?

Here’s what we heard:

“Flexibility is a key characteristic of many AERCO boilers; customization is built into our boiler designs. There are fewer limitations and restrictions in many respects, such as venting. The result is that customers can easily design a boiler system best-suited for their application. All the core features making our relaunched Benchmark boiler high-performing are still included, but it has the flexibility for customers to select additional features, such as dual returns and oxygen monitoring, based on the application’s needs and budget.”

— Christian Zapata, product manager, AERCO

“We have a large team of engineers at our various factories in Europe who create boilers according to our North American requirements. Sometimes it may be modifications during the lifespan of a product. The process is complex as it is not only creating a product or perhaps a feature, but also testing to ensure the highest levels of safety and quality, adding and qualifying new suppliers when needed, updating technical documents and certifications, etc.”

— Dan Moffroid, director of product management, Bosch Home Comfort

“ECR International can offer customized solutions for our customers. This has always been part of our business model.”

— Joe Langlois, executive director of engineering and marketing, ECR International

“IBC has always been focused on making the installers’ job as easy as possible, so over the years we have incorporated many features into our boilers as standard that are optional extras with other manufacturers. IBC boilers are fully customizable through our universal V-10 touchscreen boiler control used in the SL, CX, VX and EX products. 

“Easy to set up and monitor, features include express setup, advanced diagnostics and intuitive alert system — and plain English warnings and error messages. Contractors can also seamlessly integrate BACnet-enabled boilers into current building automation systems.”

— Mike Senk, product specialist, IBC Technologies USA

“Most of our boiler and water heater solutions can be configured to meet unique design specifications. We offer a package systems solution to help customers find a complete integration solution design to simplify their greatest water heating challenges. We offer off-the-shelf and customized solutions. To find out more about the customization process, visit the Package Solutions section of our website.”

— Ross Brawner, product manager, Lochinvar

“Navien does not offer individual customized boilers, but every one of our boilers include two levels of settings, allowing for a wide range of customization in the field. The first level is basic installation settings to take the boiler from the box to start up and operation in a short amount of time. 

“The second level is our advanced parameters, providing multiple settings for the contractor to fine-tune the boiler to the application, with options such as minimum and maximum water temperatures or capacity, burner startup time, domestic water priority control and boiler pressure control.”

— David Hoskyn, director of product management, Navien

“Current models of NextGen can be used as a single-zone system or built out to multizone when the customer has need. All that is required is the basic primary/secondary design. In a single-zone system, we have successfully circulated up to eight loops. The bypass valve is already integrated if the customer is building out a multizone system.”

— Todd Seed, partner, NextGen Boiler

“Rinnai designs its products with flexibility of use and ease of installation in mind. We offer a wide range of solutions for almost any residential and commercial heating application. From time to time, we do get special requests for our products to be customized to meet specific requirements for the food industry, hospitality and other vertical segments. 

“For example, we do have a made-to-order process to fulfill custom assemblies. We also have an application engineering group that can assist customers with their more complex projects and installations.”

— John Kopf, senior product manager, Rinnai

“Thermal Solutions offers multiple voltages for the same boiler model. This keeps from unnecessary field-installed transformers being required, increasing the equipment and install cost of the job. The boiler can be ordered with the voltage currently in the mechanical room.”

— Dan Rettig, product manager, Thermal Solutions 

“The benefit of choosing a boiler manufacturer with a broad line of residential and commercial boilers such as Weil-McLain is that many solution options are available for all types of applications with varying needs and challenges. Additionally, Weil-McLain provides a full complement of accessory items, enabling specifiers to further fine-tune to their desire. 

“Unlike some other boiler manufacturers with limited types and sizes of boilers, Weil-McLain offers gas, oil, water, steam, standard efficiency noncondensing cast iron, high-efficiency condensing stainless-steel or aluminum, fire-tube, water-tube, sectional, mono-block, packaged and knockdown-type boilers spanning the input range of 38 to almost 9,000 MBH. 

“If assistance is needed to match a custom need, we have a wide support network of distributor professionals, backed by our own commercial specialists, territory managers and agents.”

— David DeVries, director of product management, Weil-McLain