I handle gas fireplace parts and technical support orders at Empire Comfort Systems. Been at it four years now. In that time, I've personally made and documented eight significant mistakes that totaled roughly $6,200 in wasted budget. The worst one happened in September 2022, and it's the reason I maintain our team's 12-point pre-install checklist today.
This article compares two orders that couldn't have gone more differently. Project A (September 2022) was rushed, no checklist, assumptions made. Project B (November 2023) followed the checklist step by step. The difference wasn't just in cost—it was in trust, time, and a supplier relationship that almost fell apart.
Why Compare These Two Approaches?
Both orders were for Empire Comfort Systems gas fireplace installations—standard residential work. Same product category, similar complexity. But the path to completion diverged sharply. The main variables: whether a pre-install verification checklist was used, and whether the specifications were confirmed before ordering parts.
Here are the three critical dimensions we compare: gas log set selection, solenoid valve specification, and wall heater clearance requirements. Each one had a clear winner and loser—not gray area, not "both have trade-offs." I learned the hard way.
1. Gas Log Set Selection: Wrong Dimensions vs. Confirmed Fit
Project A: The call came in, the customer needed a 30-inch gas log set. I looked at the fireplace model number, thought I knew it, ordered the set. On paper, it matched. But the fireplace insert had a different interior depth than what I assumed. The gas logs stuck out half an inch past the face. The customer noticed immediately on delivery. We had to reorder, eat the return shipping, and pay a rush fee. Total cost: $890 in redo plus a one-week delay. That's not counting the embarassment when the installer called me to ask if I even checked the specs. (I hadn't.)
Project B: The checklist requires verifying the fireplace model's actual dimensions against Empire's compatibility guide. I pulled the guide, measured the interior opening twice, then confirmed with the customer's installer. Gas log set fit perfectly on first install. Saved roughly $890 in potential redo costs—though I don't track opportunity cost closely. Let's say it's at least $800 saved.
Lesson: 5 minutes of verifying dimensions beats 5 days of corrections—and saves about $800 per mistake.
2. Solenoid Valve Specification: Voltage Error vs. Correct Order
Project A: We needed a replacement solenoid valve for an Empire wall heater. The customer said "solenoid valve" and I ordered a 24V model because that's what we commonly stock. Turned out the unit required a 120V valve. The wrong part arrived, installation halted, technician wasted a trip. The mistake cost $450 in wasted part and labor for the redo. Plus a one-week delay. The customer was not thrilled. (Understatement.)
Project B: The checklist includes a step that says "Verify voltage of existing solenoid valve or cross-reference with unit serial number." I called the customer, asked them to read the voltage stamped on the old valve, then cross-referenced with Empire's parts database. Correct part ordered, installed same day. No extra cost.
So glad I added that voltage verification step after Project A. Almost skipped it—was feeling rushed that November morning. But I checked it anyway, which saved about $450 and a week of headache. Sometimes the boring checklist step is the one that saves you.
Lesson: The solenoid valve voltage mistake was avoidable with one phone call. Saved $450.
3. Wall Heater Clearance Requirements: Ignored vs. Confirmed
Project A: The customer wanted a wall heater installed in a closet. I assumed standard clearances applied—a fairly straightforward case. But the unit's clearance requirements specified 12 inches from combustibles on the sides, and the closet only had 8 inches clearance to the wall. We caught the error when the installer inspected the site. The inspector flagged it, installation couldn't proceed. That mistake resulted in a 3-day production delay and the customer had to modify the closet—at their own cost, but they blamed us for not flagging it upfront. Fair point.
Project B: Before ordering, the checklist prompts: "Verify installation location meets Empire's minimum clearance requirements." I asked the customer to measure the space or send a photo. The location had 10 inches clearance—just enough for the unit we recommended. No issues, no inspector flags.
I have mixed feelings about this one. On one hand, the building code is the installer's responsibility. On the other, we lost credibility by not mentioning it early. The checklist adds maybe 3 minutes to the process, but it saved what could have been a much bigger problem.
Lesson: Checking clearances before ordering a wall heater saved us from a 3-day delay and a frustrated customer.
So What's the Bottom Line?
Here's what I tell my team now: if you're ordering gas fireplace components, wall heaters, or propane heaters from Empire Comfort Systems—or any supplier—take the 12 minutes to walk through a pre-install checklist. This is not a theoretical ideal. In Project B, the checklist approach saved an estimated $1,200 in direct rework costs (gas log set reorder + solenoid valve replacement), avoided a 3-day delay for the wall heater clearance issue, and kept two customer relationships intact. In my first month using the checklist, we caught 47 potential errors across the team—roughly $4,800 in potential rework avoided.
Now, to be fair: the checklist is boring. It makes you look things up, call customers, pull up spec sheets. It slows down the ordering process. But that 12 minutes of verification beats 5 days of corrections every single time. At least in my experience.
If you're debating whether to use a pre-install checklist for your next order, consider this: the cost of not using it is probably goign to be at least $800 per mistake, based on my personal track record. The cost of using it is about 12 minutes of your time. That math works for me.
Prices as of 2024; verify current rates for solenoid valves and gas log sets. These reflections are from personal experience—your mileage may vary, especially with different product types or installers.
