Callahan Air Conditioning Pros

Boiler Replacement | Callahan Air Conditioning Pros
Wayne, NJ • Heating • Hydronic

Boiler Replacement

If your boiler leaks, locks out repeatedly, or struggles to heat the home evenly, replacement can restore comfort and lower energy use. We evaluate your emitters and heat loss, then install a right-sized system with proper piping, venting, and controls—documented and commissioned.

When Replacement Makes Sense

  • Cracked/leaking sections or corroded heat exchanger
  • Obsolete parts or repeated major repairs each winter
  • Unsafe combustion/venting or CO concerns
  • Rising bills and uneven heat due to oversizing/short cycling
  • Adding radiant zones or expanding the hydronic system

Your Upgrade — What Changes and Why

Right-sizing. We size to your home’s heat loss (not the old nameplate) to reduce short cycling and improve comfort.

Piping corrections. Primary/secondary loops or a hydraulic separator to stabilize flow and protect the boiler.

Venting & safety. Chimney liner (standard) or sealed PVC/PP venting (condensing) with combustion analysis.

Controls & reset. Outdoor reset curve tuning for steady heat and lower fuel use; DHW priority if needed.

Zoning upgrades. Circulators/zone valves sized to loop lengths; balancing and purge points added.

Domestic hot water. Combi option or an indirect tank for strong hot-water recovery.

Replacement Day — What to Expect

  1. Protect work areas and drain/flush the old system safely.
  2. Remove old boiler; prepare venting and gas/electrical connections.
  3. Set and level new boiler; install piping, pumps/valves, and separators.
  4. Install expansion tank, air separator, PRV/backflow, and relief valve.
  5. Purge, pressure test, and fill; verify design flow and temperatures.
  6. Program reset controls and thermostats; confirm DHW integration.
  7. Commission: combustion analysis, safety checks, and owner walkthrough.

Boiler Replacement FAQs

Do I need new radiators/baseboard?

Usually not. We design water temperatures for your existing emitters; upgrades are optional for comfort or aesthetics.

Standard vs. condensing—what’s best?

Condensing models excel with lower return temps (radiant/oversized radiators). Standard cast-iron suits higher-temp baseboard. We’ll recommend based on your system.

What about the water heater on my chimney?

If we remove the old boiler from a shared chimney, we address the “orphaned” water heater with a liner or alternate venting as required.

Any maintenance after replacement?

Yes—annual service: combustion check, heat-exchanger cleaning (for mod-cons), expansion tank and safety verification, and system purge if needed.


Related Services

Service Areas

Local to Wayne with seasonal maintenance across nearby towns.

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