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Initial Failure Rate of Modern Electronic Boilers
Comments
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I appreciate and
am impressed by the Euro's technology. Their installation manuals, and how they approach the installing contractor SUCKS!
I have my share of learning curves with referance to the "Euro" style of installation manuals as well. Nice technology but very european mumbo jumbo. It seems they've put the cart before the horse in order, to make a buck.
Although the Ultra is of Euro design, they're installation manuals are well thought out and suited for the American market. If the major Euro players want to sell their product here, they should make an effort to to accomadate the needs of the installing contractors.
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Right Matt
having Ken back brings a nice balnce to the wall. Feels like old times again.
Nobody tell Frank from Phillie.
Scott
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Its O.K. Steve
tell em about shrinkage !
Like a scared Turtle
Scott
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Hey Mark...
... should Viessmann be responsible for the condition of goods when shipping and handling? I thought that was the freight company's responsibility. You don't expect them to drive their goods in their trucks to your front doorstep, do you? In the absence of 100% control of the distribution chain, this can happen to any manufacturer.0 -
Perry,
First off, I'm sorry to hear that you a hard time with the Vitodens install due to the faulty wiring. Viessmann would do well to install a idiot light on the Vitodens to point out that kind of problem. They're cheap, reliable, and allow the contractor to save a couple hours of soul-searching as in your case.
It's also less than fun to have to remedy OEM mistakes on your own nickel and dime. But, at 6 hours, it's relatively modest in scope compared to some teething pains that US mod-con boilers experienced. Between loose gas connections, faulty blowers, miswired connections, and other issues, there are plenty of design and implementation problems to ensure that every manufacturer gets a black eye, if you look hard enough.
So, as angry or disappointed as you are to receive a defective piece of equipment, consider that the representative did stop by to assist the installer, found the problem, and corrected it. From now on, I'd expect your experience with the Vitodens to be just as positive as that of the homeowners I know who own one.0 -
Hi Andrew,
I think you're right, the manuals are technical, they require reading and perhaps re-reading, and perhaps they assume too much technical proficiency from the get-go. That is why courses in Warwick, etc. are as important as they are.
That said, I can't think of another manufacturer that publishes as much technical information about their goods as Viessmann does. As an example, just look at the recharge curves they publish for their Vitocells. For designers, all the blocks are there to build a nice system, once you've done the homework.
I know that Jim McCarthy always likes to get feedback on how to make the manuals better, so if people see performance improvement potential, they should send notes back to Viessmann so Jim can implement them.0 -
you bring up a good point
an internal miswired defect shows the individual unit was not tested at the completion of manufacture. I wonder how many and which brands ARE tested individually?0 -
Having spent
much of a day at the assembly plant in Germany a few years ago, I witnessed first-hand what goes on.
I also had the opportunity to see the W/M factory, the Burnham factory, the Aerco factory and the HTP as well.
Which is another reason I prefer to buy American whenever possible.
Seeing is believing.
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information
Dont get me wrong, I appreciate the depth of information in those manuals as much as anyone. It frustrates me when manufacturers do not include even the most basic design information with their products. Try finding an indirect water heater manual that contains even close to the amount of information the Vitocell manuals include. I ended up drawing some programming diagrams in cad in order to help with the setup process for RE's customers. Seeing each actual screen rather than just "setup......D" seemed to make things more clear. It did help when they started including the quick startup guide. Prior to that, it took a while to sort it all out. Yes, everyone should read and re-read the manual before beginning an installation, but people just dont do that very often. They want to cut to the chase. As the system designer I felt it was my responsibility to make the installation as straightforward as possible. If a contractor had a good first experience with a system I designed, he was obviously much more likely not to go somewhere else next time.
Having said all that, I would like to thank Viessmann for actually including the engineering data they do in the manuals.
-Andrew0 -
Not sure I agree...
... a short test on a manufacturing line may or may not catch an intermittent fault.
One shining example was a plant tour at a US manufacturer that included live firing of all burners. Sounds great, except that the test did not catch NG pressure regulators that were installed in reverse! Because the test pressure was low, no-one ever caught that problem on the assembly line... but the installers in the field probably had a field day trying to figure that one out.
At another US manufacturer, the assembly teams were empowered to re-write the assembly instructions to make their jobs easier and quicker. Sounded great, until someone from engineering noticed that the controls were being installed wrong, as the assembly team didn't know better.
Manufacturing is manufacturing... doesn't matter where it happens or who does it, the rules of the universe apply to everyone. Ideally, someone sits down and does a FMEA analysis to pinpoint the biggest potential problems and how to detect them.
As I mentioned before, given how sensitive the Vitodens is to mismatched wiring coming into the unit, an idiot light sure would help everyone detect this sort of an issue sooner than later. The cost would be pretty negligible.0 -
error
Someone got the wires backward on the 40 plug when assembling the power module. It happens. Human error knows no borders.
-Andrew0 -
Reliability
Since 98% of every boiler I install is a Viessmann, allow my 2C. I've seen 2 bad pressure switches, a motherboard, internal smart pump, and a gas valve in warranty failure with the Vitodens model. Over 20 installed...Easy to fix, sometimes tricky to troubleshoot.
No machine is perfect. No Company is perfect either. Viessmann does better than most.
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Hey Connie
I didn't purchase the "shipping company", I purchased a Viessmann Vitocel 300.
The one that we finally ended up using was still dented AND Connie, it has marks on it from the foam cradle it was packaged in. I asked about this and was ytold that it is not uncommon since the tanks come over by ship. The North Atlantic gets pretty rough and the cargo gets shifted around. Hence, the marks.
So you would have no problem if the new Mercedes you buy has a few gouges in it? After all, it's not Mercedes that is at fault right?
Puhleeze.
Mark H
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For clarification on this discussion
The miswiring was in the power supply module and cable. Not in the boiler. It may be that the boiler was tested.
The power supply is a separate box (the white box to the left of my boiler on my "install" thread), with a plug for a recepticle - and then a cord and a different "outgoing" plug that is plugged into the boiler to power the boiler (plug 40).
I am not sure if Viessmann test the boilers or not. I wonder - do they test that the power supply is wired right.
However, whereever the miswired component problem was - the general point of this portion of this thread... who's responsible ... is certainly a valid question.
Perry0 -
Allow me to disagree...
If you don't like the condition of a product being shipped to you, it is your right to refuse delivery and ask for another one. My Vitocell somehow made it through without marks, dents or other issues. Then again, I am much closer to their Warwick distribution warehouse than you are... and given how I have seen some shippers handle their product, I'm surprised that more is not broken by the time it arives on site.
Most memorable was the first-hand account of heatpumps being readied for installation in a large new subdivision in Maryland. Why bother with lifting the units off the back of the trailers when kicking them out as you go gets the job done too? How far should the responsibility of the manufacturer go when gross abuse like this happens?
As for your Mercedes analogy, I believe it is faulty as it would only apply if you imported the car yourself. If you buy the car at a US dealership, then the car company "owns" the problem right up to the point when you take ownership of the car. Thus if there are gouges, dents, etc. then that's something the dealership, MB, and the shipper have to resolve, not you.0 -
Allow ME to disagree this time
I suggest that the manufacturer of Viessmann AND Mercedes ARE responsible!
Are they not the ones that "choose" who will represent and handle their product? If that rep, or wholesaler for that matter, fails in any way, is it not the selection process of who will; and, who will not - market the product's fault for having engaged a less that ideal "partner"?
With the unique vertical marketing strategy Viessmann deploys almost identical to our "friends" at Lenox, the scorched air equivelent of Viessmann, they obviously WANT to control everything from the manufacturing elements to the actual installers! By doing what they do, they become wholly responsible for everything, except the customer. And. given the inquiry/referal system they use, they even control the end user to an alarming degree as well!
Once again, it seems to be about marketing, at the expense, I argue, of genuine product superiority.
Other than Lenox, I have never seen a product so vertically "controlled." IMHO, this is an unhealthy scheme.
In the euro mind however, this is the way to "control" the marketplace, i.e., micro-manage a product that would not fare as well in a truly open-market environment.
The union labor mentality of europe being what it is, perhaps Viessmann has no option? The private vs. public company formation seems to be of little interest as well.
I would like to know when they plan on releasing the steam boiler line.(;-o)0 -
Interesting Viewpoint
I guess we have to agree to disagree.
And, until Viessmann or Mercedes "own" the distribution chain the way Lennox does, I wouldn't compare their distribution strategy. Like all US manufacturers I know of, Viessmann distributes via wholesalers, to local distributors, to contractors.
Mercedes does not "own" the outlets either, they simply "own" the product until it's in the hands of the local dealership. Thus, while it takes distribution a step further than Viessmann, it still doesn't control the final point of sale like Lennox is attempting to.
So, as I see it, Viessmann has as little control over their distribution chain as any other manufacturer retailing via the same kinds of retailers. How else would Steve Ebels find hacked Vitolas in his neck of the woods? And who called him to fix the mess?
For that matter, if Viessmann distribution was as tight as you describe it, why on earth would they have allowed a company with a zero record of installing Vitodens', no Vitodens I&O factory training, and a owner that publicly criticizes all things Viessmann buy and install one?0 -
Connie,
whether they actually "own" the supply chain; or, have absolute control over it, is a moot point. Wouldn't you agree?
Your notion of just how loose Viessmann's network is, is based on fantasy, not reality. If you are one of the chosen few, you get attention. If you buy as a true "independent," all the factory "support" disappears. Not only does it dissappear, but silence and scorn (for not being part of the "team") are evident. Just like Lenox I might add.
It is rather obvious from your e-mail address, you have moved from mere homeowner, to self-proclaimed expert and the Viessmann poster-boy as well?
My how things change...
Or have they?0 -
Rule number 1
In troubleshooting ANY piece of equipment, never assume even the most basic of components or assemblies are right.
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Rule # 2
Be smarter than the equipment your working on.0 -
Perry
If I read correctly, the miswiring was on the 40 plug from the power module and not on the boiler itself, correct? If so, that would explain not being "caught" when the boiler was test fired. As I understand their testing, the boilers are all fitted to a common test stand and run through their paces. The power module used would be a part of the stationary stand and not the one shipped with the boiler.0 -
Ah Ken...
... your post brings a smile to my face. My e-mail address here hasn't changed in years, nor has my status as a happy homeowner.
Let me know when Viessmann makes me a poster boy so I can start collecting residuals cheques :-P
In the meantime, I guess we'll have to continue to disagree on certain topics, and that's OK. The world will keep on turning. Good night!0 -
Interesting observations about the Vitodens instructions Andrew.
My personal problem with such was the opposite--the instructions seemed written by Germans for "American" systems. It took me months to verify that the low-loss header was not needed in my system. It just seemed stupid to use primary/secondary piping and pumping when the boiler's HX and built-in circulator were fully capable of delivering the necessary flow and all available heat energy to the system. Especially stupid when such [seemed] in my mind to be contrary to efficiency.
And yes, I have radiant floors--in baths--but plan to try a much larger area in the next few years.0 -
misconception
often theres a misconception that a manufacturers rep. is the 'wizard' of the company, not true. the wizards are back in the R&D room, they are who the rep. calls for help.
thats how I have seen it.0 -
agreed
We ran into that too. It was as if no one though we were bright enough to determine whether the flow required could be pushed through the heat exchanger. Then we started making our own stainless low loss headers and that really raised some eyebrows. In general, recommending the LLH covers everything and minimizes confusion. But with a 6-24 or an 11-44 you do not necessarily need the LLH depending on the heat load, particularly if the system has low head loss. I'm not the smartest guy in the world, but you dont have to be to figure simple things like that. I started putting together sheets like the one attached to help clarify the settings. Hopefully they dont mind me posting it.
-Andrew0 -
Made in America
It is quite possible that such Aluminum castings are made here in Wisconsin. I live in about the middle of the Aluminum industry in Wisconsin - and I know that Wisconsin is one of the industry leaders in the casting and other fabrication of Aluminum components (and has been for decades).
One caution on this tale though... I know people who work in the foudries. They tell me that about 2/3 of what they are making in America is being designed overseas. I can easily see someone buying the design from overseas and then handing the prints off to an American foundry.
I think what is being looked for in the context of the post above is a mod/con boiler that is both designed in American and made in America.
Does anyone know of anyone who has designed their Aluminum HX for a mod/con in America?
Perry0 -
Perry
I believe the Slant Fin Bobcat has an aluminim HX designed and built here?
I also understand most aluminum production is done in Iceland these days due to low electric rates. Aluminum, fom bauxite is a real energy heavy process.
hot rod
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That's what I recall also...
...perhaps Noel will get on his bicycle, pay us a visit, and give us some info on this boiler since there doesn't seem to be any info on the Slant/Fin site yet.
You are correct re: the production of primary Aluminum. Yet, considering how much of the stuff is being recycled these days, it is possible to source ingot from secondary sources in the US. Remelting existing Al is a lot less energy intensive than refining ore, IIRC. You may have to "sweeten" the secondary Al with primary to get impurities low enough, but that's pretty well understood.
Sourcing the stuff in the first place has become a lot more hazardous, I hear. Between the ravenous appetite of China for the stuff and worldwide demand, everyone in industry is suffering from the high cost for Al that has resulted.0 -
Made & Designed in America
Just wanted to respond to clarify that both Dunkirk and Utica boilers are made and designed in the United States for North American applications. The castings are made in Syracuse, NY (our cast-iron castings are made in Wisconsin), our fabrication facility is in Dunkirk, NY and the assembly in done in Utica, NY.
Maggie Reed Lutz - ECR InternationalThere was an error rendering this rich post.
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?
I find your condescending, passive/aggressive tone not worthy of an answer, as you are an active shill for one and only one boiler company.
Good day.
Noel0 -
HR and Perry...
I think the trend is not towards aluminum, but away from it!
Stainless being what I perceive to be the cutting edge material.
At least two American boiler companies are involved with ceramics. One of which was doing R&D over ten years on the material. And no; it is NOT a euro enterprise, nor is the technology.0 -
You
Noticed that too?0 -
??
Noel,
First off, I apologize unreservedly for offending you. That was not my intention.
Hopefully, you can put your apparent emnity for me behind you some day. I very much wish for the two of us to get along; I appreciate your thoughtful commentary on steam and other heating systems. With help from experts like yourself I believe that Slant/Fin will continue to thrive... there is no reason that a US manufacturer couldn't compete worldwide in the hydronic heating arena.
It may strike you as odd, but my interest in the Bobcat is genuine, since it'll be the one of the few "homegrown" condensing/modulating boilers on the market. Most US manufacturers simply private-label EU mod-con wares or assemble their mod-cons from parts largely sourced overseas.
I believe that this approach puts them at a potential disadvantage to local producers for several reasons. Yet, despite announcing the product in the past, there is no info for the Bobcat on the Slant/Fin site. Can you give us an update on when it will be released (if it hasn't been already) and what the specs are?
As for the shill characterization, I disagree with it because the definition of shill does not match my affiliation with Viessmann. Plus, I frequently mention other brands like Buderus, Burnham, HTP, NYT, TT, etc. as well. But if you want to believe that I get paid by Viessmann to tout their wares, I can't stop you.
So, once again I hold out my hand in friendship and hope you take it. Cheers!0 -
Thank you
Thank you for the information, Maggie.
-Andrew0 -
cast aluminum
Away?? cast aluminum transfers heat 3x better than Cast iron and something like 5x better than stainless..
why lean away from something that works better??0 -
units
Cast heat exchangers are generally thicker than stainless steel. Thermal conductivity has units (btu-in)/(hr-ft^2-°F). 6061 Aluminum is around 10x better than 316 stainless steel. 316 Stainless is around 2x better than gray iron. So yes, aluminum far exceeds other materials' thermal conductivity. However, manufacturers can play with the thickness and surace area to achieve the heat transfer rate they desire.
I have more concerns about corrosion than about performance. I am not a materials scientist, but aluminum in the presence of copper and iron mixed with the potential for pH problems is not currently something I would like to risk. Only time will tell.
-Andrew0 -
But aluminum appears
in the latest offering from Weil, Burnham, Utica, Crown, Buderus, Slant Fin, MZ to some extent, and a few I have lost count of.
Of the boilers at ISH Chicago half had an aluminum block.
All materials have pros and cons. Time, only, will tell which last. I suspect like most hydronic products different areas will see different problems. Water quality being the biggest unknown and the hardest for installers to define, test, and treat properly.
Ceramics may be an option or composite products?? I've already seen composite body wet rotor circ prototypes. Who knows? I predict the installer will be the key player in the R&D piece of the puzzle
hot rod
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They're not
Plain Jane aluminum.
They are laced with alloys.0 -
Just as there are dozens of stainless alloys
some Euros swear by the Ti stabilized stainless.
I've noticed a switch to 409 by many of the fired vessels and even indirect manufacturess have played around with various grades of stainless to get the best of all worlds.
Stainless has plenty of weak points when fire, pressure, abnormal water conditions and thermal stress are thrown at it. Some times different grades are used in one product to leverage the strong points of the various alloys.
Back to the cast iron, boat anchor kettles (boilers)of days gone by??
hot rod
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Plus,
... there are cost considerations. Much engineering is figuring out how to cost-optimize... take the Monitor FCX for example. It has a steel combustion chamber in the non-condensing section, and a stainless chamber in the condensing section. Some European boilers (like Ryll) go as far as having plastic secondary heat exchangers.
One of the holy grails in engineering is a cheap HX that can take cycling, hot gases, and is cheap to manufacture. They could instantly boost the efficiency of microturbines and other such devices by 50%+... yet to date, only stainless HX seem to be used in that application, curtailing their adoption (up front cost vs. payback). Research continues in ceramics, to my knowledge no one has achieved a breakthrough that allows a cheap, effective, rugged air-air HX to be constructed in that application.
With the right protection, plastic secondary heat exchangers may be the answer in a residential setting. How to get those HX's past ASME and other orgs is for someone else to figure out. Never mind liability issues like the safeties getting jumpered, incorrect installation methods (clay chimneys w/o proper liners), and so on.0
This discussion has been closed.
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