We manufacture over twenty-five models of high efficiency, stainless steel, condensing boilers and water heaters with a nominal rating from 200,000 Btu/hr – 12,000,000 Btu/hr.
Our condensing boilers have several advantages over conventional boilers. These are a few advantages that you can benefit from by retrofitting your old boiler with a state of the art condensing boiler.
Gasmaster condensing boilers can regulate the heat input to match the demand of the system. Due to the construction of the heat exchanger, there is no concern about condensation at lower firing rates and this allows the unit to match the load of the system. Fuel consumption is therefore reduced as the boiler does not have to constantly switch on and off.
Gasmaster boilers and water heaters have a very small footprint and provide savings on installation costs when retrofitting boilers. They eliminate the need to dismantle and remove the old conventional boilers, although we do offer that as a service if requested.
Due to the energy efficiency of condensing boilers, they burn much less fuel to provide the same amount of heat as compared to the conventional boilers. This can mean considerably lower fuel bills for your building or business.
In most space heating applications, designers are limited by the return water temperature requirement of conventional boilers. In most cases, heating systems are designed to allow for only 20-degree temperature drop, to ensure return water temperature remains above 60 °C (= 140 °F). This is to avoid possible condensation, which will result in almost immediate and permanent damage to the boiler.
In contrast, Gasmaster boilers offer the engineers the opportunity to design heating systems for maximum efficiency without the return water temperature as a limiting design factor. Not only does this feature result in significant cost savings (elimination of mixing valves and secondary loops), it also allows for the design of highly efficient heating systems.
Due to the high efficiency of Gasmaster boilers the carbon dioxide emissions are reduced so the total contribution to global warming is also reduced. Because of this, they are much more friendly to our environment. The level of NOx content in the exhaust gases can be as low as below 15 ppm.
During the past decade, regulatory authorities, both in the US and Canada, have been reducing the allowable level of NOx emissions. At present, the allowable level of NOx emissions in most states is around 80-100 ppm. However, several states like California, Texas and other jurisdictions have reduced the allowable levels to 30 ppm.
Unlike conventional boilers which are constructed either from cast iron or copper tubing, Gasmaster boilers incorporate ASME approved stainless steel heat exchangers. All other sheet metal components (boiler housing the condensate tray) are also made of stainless steel. The choice of high-grade stainless steel increases the useful life of Gasmaster boilers well beyond that of conventional boilers while reducing the energy costs and increasing system efficiency.
The average efficiency of Gasmaster boilers is 95.6%, which is approximately 15%-30% higher than that of conventional boilers. When switching to a more efficient boiler, the result can be substantial savings on your utility bills.
Based on 2 Million BTU/hour, 178 days/year and 12 hours/day usage, and efficiency improvements between 1 and 30 percent.
Cost of Fuel per Gigajoule
In addition to the commonly used high-temperature cut-off switch, the following sensors are installed as standard features:
A flow switch is installed to monitor the rate of water flow through the system. If this flow rate through the boiler falls below a specified rate of flow, then the flow switch will shut-off the boiler and automatically close the fuel supply valves.
Each Gasmaster unit is equipped with a high-temperature limit switch. If the outlet water temperature exceeds the temperature set-point, which is manually set, the boiler is shut-off and lock-out occurs.
A safety relief valve is installed on the water outlet manifold and supplied as standard equipment. The valve automatically releases the water when the system pressure exceeds the preset limits.
A single Low Water Cut-Off sensor and switch is installed on the outlet manifold and monitors the level of water within the piping. It must be reset manually. If for any reason the water level drops below the position of the sensor, the entire system is immediately shut off. A manual reset of the switch is required before the system is once again operational.
A single air pressure switch is installed on the blower and measures the air pressure entering the burner. If the combustion air pressure drops by more than 20% below the nominal air pressure (minimum pressure of 0.4″ wc), the burner controller will undergo lock-out and the main gas valves will subsequently and immediately close.
One manual reset low gas pressure switch is installed on the gas train in between the gas pressure regulator and the first safety shut off valve. If the line pressure drops below the set-point, the switch will open and the unit will immediately shut down. A second gas pressure switch is also installed on the side of the Riello burner, and should the gas manifold pressure increases above the set-point, the switch will open and the unit will immediately shut down. Additionally, if the exhaust path is at any point clogged, resulting in back pressure generated within the housing, the system will be shut-off.
A boiler is a closed vessel in which water is heated (not necessarily boiled). Originally used to power steam engines and ocean-going vessels, the traditional boiler was a bulky piece of machinery that was fueled by wood or coal and was difficult to clean. Firetube boilers, as they are now called, consisted of a tank or barrel of water with steel tubes running throughout. Fire would flow through the tubes and heat the water. Eventually, people realized the obvious inefficiencies in this design and created the watertube boiler, which is what we make here at Gasmaster.
Watertube boilers fill the tubes with water instead of flames and allow for higher pressure.
By condensing the water vapor that is produced during combustion and trapped in the flue gases they achieve a higher efficiency.
“Thermal shock,” or “boiler shock,” is a type of stress in boilers caused by heating, and can lead to serious, irreparable damage to the boiler, as well as danger to those around the unit. Thermal shock usually happens when cold water is sent back into a hot boiler system, or when a boiler is run at a heating capacity it wasn’t built for.
Just like how cold glassware can crack when hot liquids are poured into the vessel, when a boiler is running hot and cold water returns to the system the steel can be affected. When boilers are running, the metal expands. The cold water coming back in can cause the inlet pipe and surrounding areas to contract instead, destroying the seals, connections and even cracking the metal.
Gasmaster’s patented stainless steel heat exchangers are a state-of-the-art design that provides a unique counter-flow process and allows for the highest thermal efficiencies in the industry. The counter-flow process means that the vessel is completely shock-proof, so water can be returned to the system at any temperature.
Every Gasmaster boiler and water heater is equipped with a unique throttle mechanism. Within the operating range of each equipment, the throttle mechanism offers practically infinite modulation capability. While this can not eliminate the on/off cycles completely, it does reduce it by over 90%. Therefore, cold starts and associated pre-purge periods are almost eliminated. This directly results in an increased useful life of the water heater and/or boiler and increased overall efficiency of the equipment.
The unit’s operation is governed by the desired outlet (hot water) temperature. Using a digital, high precision temperature controller, the owner will identify the required hot water temperature. A temperature sensor installed on the boiler/water heater outlet manifold continuously measures the outlet water temperature. A servomotor controlling the gas butterfly valve and the air damper (by means of a variable profile cam mechanism) allows for throttling of the air/gas mixture flowing into the burner. For as long as the set temperature is above that of the outlet water, the boiler/water heater operates at maximum output capacity.
Analog output signals from the temperature sensor are sent to the temperature controller, which in turn sends corresponding signals to the servomotor. This throttles the flow of gas and combustion air in the gas butterfly valve and the air damper. Therefore, the appropriate volume of air/gas mixture flows into the burner, allowing for almost perfect air/gas mass, and volume ratios. As the outlet temperature approaches the set temperature, the air/gas mixture flow is gradually reduced by the servomotor (connected to the gas butterfly valve and the air damper).
This results in the corresponding gradual decrease in the unit’s capacity. Thus the throttle system allows for optimum continuous operation of the boiler, significantly reducing on/off cycles. The said system offers the user almost infinite modulating capacity within the boiler/water heater operating range.
Gasmaster boilers and water heaters offer the highest efficiency rating in the industry. The certified efficiency range in accordance to ANSI Z21.13b (latest addendum) is 92% – 99.8%, depending on the return water temperature. In addition to this highly efficient performance, Gasmaster products offer the cleanest and most environmentally friendly operation. Gasmaster boilers and water heaters operate at NOx levels below 30 ppm, with some models having NOx concentration as low as 6 ppm.
From the very beginnings of Gasmaster, we have been at the forefront of providing the world with the most efficient boilers possible. Our contributions to high-efficiency boilers include the world’s first 4 million btu/hr, the world’s first 8 million btu/hr, and the world’s first 12 million btu/hr condensing boilers.
When the Green building council was founded in 1999 we were perfectly positioned to let engineers, contractors and building owners take advantage of the technology of high efficiency condensing boilers.
Since we make nothing but high efficiency condensing boilers, every single product that ships out the door at Gasmaster can earn you valuable LEED Points.