ESSENTIAL FOR ENERGY SAVINGS
Complete Heating Pack for water compliance in the home
Inside: Heating Filter, Cleanser and Inhibitor Chemicals, Scale Inhibitor and Acidic Neutraliser... BUY WITH CONFIDENCE. COST EFFECTIVE SOLUTIONS FOR COMPLIANCE.
Water treatment
The need for effective water treatment There are an estimated 17 million gas boilers in the UK, with around 1.5 million new boilers installed each year. Following the Government’s decision to require virtually all new boilers to be SEDBUK A rated boilers following the changes to Part L of the Building Regulations, rise has been given to areas of water treatment that need to be addressed which followed with the Domestic Heating Compliance Guide. Water treatment fulfils a number of rolls within domestic central heating systems and can be summarised to minimise the corrosion of metals within the system, to inhibit the formation of the scale and sludge, to inhibit the growth of microbiological organisms and to maintain or restore the energy efficiency of the system. Boiler noise, pump failure and cold spots are problems that can be rectified by correct treatment and cleaning. Dirty central heating systems can increase fuel bills by up to 35% something that homeowners will be keen to remedy. Powerflushing is the most efficient way to pre-commission a new installation or clean an existing system. By flushing with mains water alone, around 10% of the debris in a system is removed. This can be increased by up to 30% by adding a powerflushing unit to the process.
To increase this figure even further, you can combine powerflushing with the use of chemicals such as cleansers, sludge, flux, silt and descaling chemicals, which will remove up to 80% of the contaminants present. The Building Regulations state that during the final filling of the system, a chemical water treatment formulation should be added to the primary circuit to control corrosion and the formation of scale and sludge. Added to this, boiler manufacturers are increasingly reluctant to honour warranty repairs where they suspect that the problem has been caused or exacerbated by debris or sludge in the system. Independent research carried out by GasTec has confirmed that sludge build up in radiators on a normal domestic heating system can reduce their overall effectiveness by as much as 15%. In addition, it says that proper cleansing of a system using a chemical additive to “break up” sludge deposits combined with a powerflush of the system will result in a greater uniformity of radiator temperature and result in a reduced risk of system imbalance.
Extract taken from the Domestic Building Services Compliance Guide 4.0
New Systems
Supplementary info
System Preparation and water treatment
a. C entral heating systems should be thoroughly cleaned and flushed out before installing a new boiler.
Inhibitors should be BuildCert approved or equivalent. Limescale can be controlled by the use of chemical limescale inhibitors, combined corrosion and limescale inhibitors, polyphosphate dosing, electrolytic scale reducers or water softeners. The relevant standard of water treatment is BS 7593:2006 Code of Practice for treatment of water in domestic hot water central heating systems. BS 7593 notes that “naturally soft waters of low alkalinity or those supplied via a base-exchange resin softener have an increased potential for corrosion, and if they are used in any central heating system, a corrosion inhibitor specifically formulated for the purpose should be added and properly maintained.” Manufacturers should be consulted for advice, paying particular attention to dosage levels. Special radiator valves are available that will seal off the radiator as well as the heating circuit to prevent loss of inhibitor when removing a radiator for service or maintenance. A filter can also be fitted to the central heating circuit to help maintain the efficiency and reliability of the system.
b. D uring final filling of the system, a chemical water treatment inhibitor meeting the manufacturer’s specification or other appropriate standard should be added to the primary circuit to control corrosion and the formation of scale and sludge. c. Installers should also refer to the boiler manufacturer’s installation instructions for appropriate treatment products and special requirements for individual boiler models. d. Where the mains total water hardness exceeds 200 parts per million, provision should be made to treat the feed water to water heaters and the hot water circuit of combination boilers to reduce the rate of accumulation of limescale. e. For solar thermal systems, see Section 11.
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COMPLETE HEATING PACK FOR WATER COMPLIANCE IN THE HOME
Water treatment fulfils a number of roles within domestic central heating systems which can be summarised as follows:
To minimise the corrosion of metals within the system. To inhibit the formation of limescale. To inhibit the formation of the scale and sludge. To inhibit the growth of microbiological organisms.
o maintain or restore the energy efficiency T of the system through a combination of the above effects.
These are consistent with the requirements of British Standard, which is a referenced document within the current Building Regulations, and following this Code will guarantee compliance.
The current problem In most cases, the quality of water supplied to the home is determined by local conditions. There is no practical method of external treatment at the water works, which can reduce the potential for corrosion and scale within the home. To minimise the likelihood of corrosion, scale, sludge, acidic waste and microbiological contamination, and to help us maintain the energy efficiency of the heating system, the water must be treated with the use of various products.
To neutralise and dispose acidic waste safely, without damaging the environment.
Problem:
Solution:
• Limescale can deposit on heat exchangers as soon as the boiler is heated, which will result in energy efficiency loss.
• Components, due to corrosion and erosion, need to be minimised and de-sludging of the system needs to be prevented.
POWERFLUSHING
CHEMICALS
• Black iron oxide will form within a heating system which will result in cold spots on radiators, component failure and efficiency losses.
SCALE INHIBITOR
• Condensing boilers produce acidic waste which, if not treated correctly, can be leached back into the water table, causing long term problems.
ACIDIC NEUTRALISER
HEATING FILTER
Central Heating Filter Essential solutions for energy savings The problems with untreated systems If a heating system is left untreated, or not regularly maintained, the production of sludge, in the form of black iron oxide, will take place and ultimately reduce the efficiency of the central heating. This will lead to higher energy bills, cold radiators, failure of pumps and valves, and potentially cause blockages within the system.
Most of the system debris can be removed by a magnetite removal unit which can be installed in-line and will go some way to increasing the efficiency of the heating system.
In line with current standards, central heating systems should be thoroughly cleaned and flushed prior to installation of a new boiler and one of the processes is to use a magnetite
Please note that this is only part of the solution and all systems should be correctly treated with the relevant chemical treatment wherever possible to ensure conformity to the current building regulations as stated in the Domestic Heating Design Guide and BS6798.
Introducing Calmag Filter HF2
Easy to Install
Calmag Filter removes the black iron-oxide or magnetite
Calmag Filter can be installed as a permanent product within the heating system and also can be used in conjunction with the CalFlush powerflushing machine.
removal unit.
and sludge from a heating system, restoring the efficiency of the system back to its original level. To clean, the external magnet can be removed from the housing, and the iron oxide is easily drained from the system. Calmag recommend the installation of Calmag Filter on every new system to prevent any future build up of magnetite and sludge.
Install the Calmag Filter between the heating system and the return hose to the CalFlush powerflushing machine.
Installation of a Calmag Filter unit together with the correct use of chemicals within a central heating system will ensure a more efficient operational life.
Installation 1
Installation 2 CALMAG FILTER
BOILER
CALFLUSH POWERFLUSH MACHINE
POSITION 1
BOILER CALMAG FILTER
CALMAG FILTER
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COMPLETE HEATING PACK FOR WATER COMPLIANCE IN THE HOME
CALMAG FILTER
RETURN
POSITION 2
CALFLUSH
CALMAG FILTER
CalMag Filter HF2
THE
ULTIMATE IN MAGNETIC FILTRATION
Durable and resilient Does not crack or disintegrate Withstands high temperatures - best suited for household hot water Excellent conductivity which promotes the efficiency of hot water distribution Remarkable ductility in high temperatures
25 YEAR† GUARANTEE
Powerful Neodymium magnet Versatile Unique manifold ½” BSP drain valve 500ml internal capacity
Technical Information • No ongoing running costs. • High intensity rare earth magnetic rod. • Externally removable magnet. • No need to turn off boiler to clean. • Complete installation kit available. • Easy installation - simple and trouble free. • Restores efficiency levels of central heating systems to their peak performance
•R emoves magnetic and sludge build up. • E xternally removable bowl for ease of cleaning •D esigned to ensure there is a flow through the unit at all times - even when the housing is full of iron oxide. •U nit must be installed on the return flow to the boiler
25 year guarantee on the magnet
†
Central Heating Filter Unique manifold information The Calmag HF2 Heating Filter comes complete with a unique manifold to reduce the installation and annual service time of the unit.
Manufactured from chrome plated brass for durability purposes, it ensures that the HF2 main unit can be removed at any time without any detrimental effect to the central heating system. It’s unique bypass configuration simply means that the heating can be left on whilst cleaning/ servicing is carried out, saving time and money on cool-down periods.
Unit in Service
INLET FROM HEATING SYSTEM 22MM
INLET TO HF2
Heating Filter Manifold: No flow restriction One piece
INLET VALVE/ BYPASS
Bypass manifold Ease of installation
WATER FLOW
Unit can be removed from system without loss of heat VALVE OPEN
Chrome plated brass
MAIN BRASS BODY
Durable
UNIT IS COLLECTING MAGNETITE
OUTLET TO HF2
VALVE OPEN OUTLET VALVE/ BYPASS
Unit on Bypass
UNIT REMOVED FROM INSTALLATION
WATER FLOW
VALVE CLOSED
VALVE CLOSED BOILER FOR CENTRAL HEATING STILL OPERATING
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COMPLETE HEATING PACK FOR WATER COMPLIANCE IN THE HOME
OUTLET TO HEATING SYSTEM 22MM
Chemical Cleanser
Clean, neutralise and inhibit corrosion, scale, boiler noise and hydrogen gassing CMI-500 Inhibitor has a special reagent formula which works on reaction to sludge, limescale, flux and other debris through its combination of chemicals.
Pre-commissioning cleanser for new and old systems for flushing sludge, flux and installation debris. Suitable for use with all components and will not harm aluminium or other metals. Requires no neutralisation and can also remove light rust whilst helping to descale and soften water.
CMI-500: 50Oml concentrate formula which will dose a standard system of 10 - 12 rads or 100 litres No sprays, no aerosols and is environmentally friendly Energy Saving Trust recommended BuildCert approved product
CC300 Cleanser: 50Oml concentrate formula which will dose a standard system of 10 - 12 rads or 100 litres Non-toxic. Removes flux, sludge and scale Used for new and old systems Suitable to use on all metals and requires no neutralisation
“Central Heating systems should be thoroughly cleaned and flushed. During final fitting a chemical water treatment inhibitor should be added to the primary circuit�
Combination boilers The environmental problems
A condensing boiler is a high efficiency modern boiler, incorporating an extra heat exchanger, so that hot exhaust gases lose much of their energy to pre-heat the water in the boiler system. When working at peak efficiency, the water vapour produced in the combustion process condenses back into liquid form, releasing the latent heat of vaporisation.
pH
The water, known as condensate, is produced as a side-effect and is usually acidic, containing dissolved oxides of sulphur, nitrogen, and has to be piped away to a drain. A condensing boiler from an average household will produce approximately 800 litres of acid per year* at pH4. This is not a problem for the odd house or two but the amount of acid condensate put down the drain is thought to be growing at a rate in excess of half a million of litres per week as more and more condensing boilers are installed.
-1.0 0.5 1.5-2.0 INCREASING ACIDITY
Battery acid
2.4 2.5
Lemon Juice
2.9
It’s conservatively thought that in 2 years time we could be adding in the region of 50 million litres of acid at pH4 to our drains each week. The environmental consequences are potentially huge and, until now, little interest has been shown in addressing the problem.
3.5
Vinegar
4.0 4.5 <5.0
As a reputable company we have worked alongside the BSI to identify the solution to this area which has progressed to the addition of an in-line condensate neutralising device to BS 6798:2014, named CalDensate.
5.0
Normal range of precipitation pH
5.5 6.0 6.5 NEUTRAL
7.0
Milk
6.5-7.4 7.34-7.45 INCREASING ALKALINITY
7.7-8.3 9.0-10.0 11.5 12.5 13.5
Baking Soda Sea Water Milk of Magnesia Ammonia Lye
* See table 1 for guideline condensate production Extract from BS6798 and Domestic Heating Design Guide: Condensate drainage pipe shall be positioned and terminated such that it discharges the condensate safely, away from the building. Where an inline neutraliser device is fitted the installation instructions shall include advice on the effective life, temperature limitations and method of replacement.
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COMPLETE HEATING PACK FOR WATER COMPLIANCE IN THE HOME
The effects of acidic water • Degrades copper – pin holes in pipes, cylinders etc • Damages stone, metals, paint • If drawn into the water systems it can kill off small organisms that aquatic life depend on • Can have unhealthy effects on humans, mostly through absorption into the lungs • Damages plants dependent on the soil. Table 1:
Guideline condensate production BOILER GUIDELINE SPECIFICATION CONDENSATE PRODUCTION 10KW
1 litre per hour
15KW
1.5 litres per hour
20KW
2.0 litres per hour
25KW
2.5 litres per hour
30KW
3.0 litres per hour
35KW
3.5 litres per hour
40KW
4.0 litres per hour
Please note that in most installations the removal of condensate can be achieved through gravity although in certain circumstances the use of a boiler condensate pump may be necessary. This will still require the condensate to be neutralised and therefore the CalDensate should be used alongside the condensate pump. If a pump is fitted the CalDensate should be installed before the pump.
CalDensate
Calmagâ&#x20AC;&#x2122;s money-saving solution There are a number of problems which occur when acidic water enters the water system. Simply installing the CalDensate will ensure that the pH is neutralised by means of the specially formulated media which is included in the product.
This easy to fit in-line unit is a bi-product of our own successful commercial products. The CalDensate is effective, economical and environmentally friendly due to the fact that the throw away cartridge is biodegradeable and the housing never needs replacing and therefore does not harm the environment in terms of waste in landfill sites a product on the market place with this unique feature. CONFORMS TO
BS6798: 2014
Benefits include:
STANDARD
Total acid protection
12 month life
Slimline product
Environmentally friendly
Fits all condensing boilers
Fits all condensate piping
Easy to replace cartridge
Simple connections
Suitable for high temperature
12 MONTH GUARANTEE
THE OPTIMUM
PUSH FIT
IN-LINE DEVICE ON THE MARKET
CalDensateâ&#x20AC;&#x2122;s white in-line neutraliser ensures it blends in with traditional white overflow pipes, inside the property, giving an aesthetically pleasing appearance.
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COMPLETE HEATING PACK FOR WATER COMPLIANCE IN THE HOME
Advantage of using CalDensate Advantages of using the CalDensate. No need to worry about:
• Underground cables
• Listed buildings
• Flower beds ruined
• Space restrictions
• Hard ground, ie. frost
• Replacement
• Time
• Weather constraints
• Planning permission • Paving stones
Typical CalDensate Installation 1
Boiler
2
Ground
3
In line acidic neutraliser with replaceable cartridge:- CalDensate
4
External length of pipe 3m maximum
5
Open end of condensate drainage pipe
6
Nominal diameter 22mm
1
6
3
4 2 5
New improved cartridge Through extensive research and tests we have manufactured a new cartridge which has been designed and calculated to hold the maximum amount of calcium carbonate to ensure maximum condensate discharge.
Benefits include: Maximum performance Optimum flow rate Fits neatly into the CalDensate unit
This is achieved by the purpose-designed holes within the cartridge which allows for maximum and effective flow of condensate and will not result in any blockages that may cause the boiler to shut down.
NEW AND
IMPROVED CARTRIDGE
Limescale prevention Essential for energy savings Problems caused by Hard Water Calcite, the main cause of scale, is the most common form of calcium carbonate and occurs as a natural ingredient of chalk, limestone and marble. Water passing over and permeating through such rocks dissolves calcite when this water subsequently flows through a water system the calcite participates out to form a very hard scale on surfaces. When hard water is heated, or evaporation takes place, the problems are exacerbated. Calcite forms ever growing layers of rocklike deposits until eventually pipes, jets, and equipment become totally blocked. The problem increases as the water gets hotter. Water containing 145ppm of calcite, flowing at 3.5 litres per minute, produces in one year 4.8 kilograms of scale at 60ºC. At 80ºC this rises dramatically to a massive 29.9 kilograms! Scale wastes both energy and financial resources just one eighth of an inch of limescale reduces heating efficiency by 25%. It is also very expensive to remove, descaling pipes and boilers alone costs British industry over £800m each year.
It has been shown that a heat exchanger surface with 1mm limescale deposit requires approximately 8% more energy to achieve the same output. Consequently, the energy saving benefits of a scale-free boiler are such that it makes sense to err on the side of caution. For a modest outlay, the householder will see long term benefits in terms of reduced energy bills and fewer boiler breakdowns. Research indicates that modern high efficiency boilers work at higher temperatures than standard efficiency boilers, temperatures fluctuate more, waterways tend to be narrower and heat exchangers thinner, so limescale build up has a more serious effect on performance sooner than would otherwise be the case.
Helping your customers SOFT/MEDIUM WATER AREAS
Find out what the problem is It is important to ascertain from your customer the problems they are experiencing with water hardness. This information will enable you to advise them on the correct product.
Tell tale signs
Water hardness
If you live in a hard water area, 60% of the UK does, you will know the tell tale signs - furring of appliances, scale deposits in a heating system, noisy radiators and reduced flow and efficiency.
There are two types of hardness. Temporary hardness, which comes out of the water when it is heated and permanent hardness which is unaffected by heating. Measuring the extent of water hardness and the effect on appliance efficiency is the key to providing the appropriate solution.
It is important to know the level of water hardness and putting the correct solution in place can save money.
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COMPLETE HEATING PACK FOR WATER COMPLIANCE IN THE HOME
HARD WATER AREAS
Use these charts in conjunction with CalTest results to recommend the correct Calmag product... Water Hardness Chart DEGREEâ&#x20AC;&#x2122;S CLARK
PPM
SOFT/HARD
(milligram per ltr.) LEVEL
0 0 1 14 2 29 3 43
SOFT
4 5 6
57 71 86
MODERATELY SOFT
7 8 9 10
100 114 129 143
SLIGHTLY HARD
11 12 13
157 171 186
MODERATELY HARD
14 15 16 17 18 19 20
200 214 229 243 257 271 286
HARD
21 25 29
300 357 414
VERY HARD
30 40 50
429 571 714
EXTREME
*Information taken from British Water Authority
SCALE AVERAGE THICKNESS (mm) EFFICIENCY LOSS 0.4 4% 0.8 9% 1.6 1% 3.2 2% 4.8 30% 6.4 40% 9.5 55% 12.7 70%
Scale Potential 100 ppm will give 1lb/0.5 kg scale potential per 1,000 gallons/4546 litres of water.
Example Hardness level = 300 ppm Water used = 2,000 gallons/9092 litres
Total Scale Potential 3lb x 2 = 6lb scale per day 1.5kg x 2 = 3 kg scale per day
CalLytic Electrolytic Scale inhibitor
Where mains water exceeds 200ppm provision should be made to reduce the rate of accumulation of limescale which can be controlled by the use of CalLytic Electrolytic scale inhibitor.
PROLONGS THE LIFE OF BOILERS
5 YEAR GUARANTEE
Key Benefits: What they are... Scale inhibitors are installed to reduce, prevent or remove the formation of hard (lime) scale in domestic hot and cold water systems or for scale and corrosion inhibition in central heating systems in areas which are supplied with hard water. It is acknowledged that the assessment of some aspects of water quality can be very subjective and personal, and so any other changes in water quality should be regarded as extra benefits rather than being part of the reason for installing a scale inhibitor. The main reason for the installation of a scale inhibitor is for scale reduction and/or scale removal.
Whole house protection 5 year guarantee Conforms to current Building Regulations Prevents lime scale formation and removes existing lime scale Can prolong the life of boilers
What they are not... Scale inhibitors do not remove the hardness minerals and so they will not provide softened water. This is why they are called inhibitors. This is one of the factors which differentiate them from water softeners which change the chemical composition by replacing the calcium and magnesium with sodium from a salt (brine) solution.
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COMPLETE HEATING PACK FOR WATER COMPLIANCE IN THE HOME
WRAS approved
Easy step solution for water compliance in the home
1 Scale
Inhibitor
2 Inhibitor
CLOSED HEATING SYSTEM
3 Cleanser
3
CONDENSING BOILER
2 4
Filter
1
INCOMING COLD FEED
KEY:
5
4 Heating
HOT WATER SUPPLY
COLD WATER SUPPLY
5 Condensate
- WORKING IN ASSOCIATION WITH -
Guaranteed
confidence in water quality Calmag’s fresh, innovative approach to water quality has led to the development of the most extensive and effective range of water treatment solutions within the UK water treatment industry – our products are designed with the needs of our customers in mind – the merchant, installer and consumer. Calmag’s philosophy is based on providing products and services to meet the real needs of all our customers – we don’t simply produce what we think you should buy - Calmag have the unique design and production capabilities to produce what you want - when you want it!
Beware of imitations!
TY I L D E QUA R U D ASSD TESTE
There have been a number of instances when customers have been under the impression that they have bought a Calmag product but, in reality, have been supplied with an alternative and inferior product that fails to match the industryleading performance and aesthetic appeal of ours. So we strongly advise customers to ask for our product by name. Other products may seem to offer similar qualities, but if it isn’t Calmag, it simply won’t perform to our standards.
AN
There are two key ways to check that you’ve purchased a genuine Calmag product: they carry the WRAS approval on scale inhibitors, and BuildCert and ESTr approvals on a range of chemical inhibitors.
Calmag is a member of and in partnership with:
UV Disinfection
Water Softeners
Water Filtration
Powerflushing
For more information regarding all Calmag products and services please go to www.calmagltd.com Calmag has a policy of continuous product development and reserves the right to alter any specifications without prior notice. Copyright Calmag Yorkshire Limited. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior consent and permission of Calmag Yorkshire Limited. Calmag Yorkshire Limited hereby exclude all liability to the extent permitted by Law for any errors or omissions and for any loss, damage or expense (whether direct or indirect) suffered by a third party relying on any information contained in this brochure. * All figures are taken from various published figures
01/17
Tel: 01535 210320 Fax: 01535 210321 Email: sales@calmagltd.com