Calming troubled waters

PowerflushingMade easy

Call for further information 01535 210320Fax: 01535 210321 | Email: sales@calmagltd.com | www.calmagltd.com

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ESSENTIALFOR ENERGY

SAVINGS

INSTALLERS-CONFORM TO THE CURRENT BUILDING

REGULATIONS

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IntroductionThere 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.

New Systems Replacement Systems

4.0SystemPreparation and water treatment

a. Central heating systems should be thoroughly cleaned and flushed out before installing a new boiler.

b. During 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, and if required by the manufacturer, 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.

a. Flushing

b. Chemical

d. Limescale

MAKE SURE THAT YOU FLUSH!

• Tominimisethecorrosionofmetalswithinthesystem.

• Toinhibittheformationoflimescale.

• Toinhibittheformationofthescaleandsludge.

• Toinhibitthegrowthofmicrobiologicalorganisms.

• Tomaintainorrestoretheenergyefficiencyofthesystemthrough a combination of the above effects.

• Toneutraliseanddisposeacidicwastesafely,withoutdamaging the environment.

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 the 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 a 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.

• Limescalecandepositonheatexchangersassoonastheboiler is heated, which will result in energy efficiency losses.

• Components,duetocorrosionanderosion,needtobeminimised and de-sludging of the system needs to be prevented.

• Blackironoxidewillformwithinaheatingsystemwhichwill result in cold spots on radiators, component failure and efficiency losses.

• Condensingboilersproduceacidicwastewhich,ifnottreated correctly, can be leached back into the water table, causing long term problems.

Problem Solution

Scale Inhibitor / Water softeners

Powerflushing & Chemicals

Acidic neutraliser & new cartridge

THE ABOVE ARE RECOMMENDATIONS FOR ALL INSTALLERS TO FOLLOW AND COMPLY WITH THE CURRENT REGULATIONS

Used cartridge

Water treatment fulfils a number of roles within domestic central heating systems which can be summarised as follows:

The Professional Choice For Power Flushing

NEW improved CalFlush units...

Central heating systems can gradually build up a combination of scale, sludge and corrosion by-products within the boiler, pipework and radiators. This manifests itself as cold spots on radiators, failure to pump to the furthest radiators and noise in the boiler.

Central heating systems also need to be flushed prior to filling with preservative, in order to remove flux and other deposits, before commissioning for the first time (BS7593:1992).

It can often be time consuming or impractical to remove radiators for cleaning out severe blockages. Even when radiators are removed, the only flushing capability often available is with a hose at mains pressures and flows, however, this process will not loosen or remove sludge which has bonded to the inside of radiators, or the remainder of the heating system.

The Calmag CalFlush is the culmination of many years experience of the use of Calmag’s chemicals with high flow, low pressure cleaning sets.

Fouled heating systems can be cleaned, whilst in normal service, with Calmag products which are left in the system to recirculate for a period of a few days. However this requires multiple visits to the site and often involves frequent draining down and refilling to restore badly fouled systems. This process can be simplified and shortened by recirculating the cleaning solution at a high flow through the system, while alternating the direction of flow. Thorough cleaning can be completed in a short time with high efficiency and minimal disturbance to the existing heating circuit.

Homeowners may require an explanation of Powerflushing to make it clear how this benefits a heating system and helps to prevent system breakdowns. The best way to promote the sale of Powerflush to customers is to cut a heat exchanger in half, and show them exactly how small the water ways are. This helps to demonstrate how quickly water ways could block if a new boiler is added to a dirty heating system.

CALFLUSHSuitable to powerflush 20/25 radiators max and up to 45ft or 2/3 storeys high, and max flow rate of 50L/min

CALFLUSH MAXSuitable to powerflush 40 radiators max and up to 66ft or 3/4 storeys high, and max flow rate of 150 L/min

Problems Areas That Powerflushing Will Cure

1. Sludge build up at the bottom – cold.

2. Trapped air at the top – cold, due to gases.

3. Blocked valves and pipes – cold.

4. Boiler – no circulation from blocked pump.

5. Boiler noise and boiler cut-outs due to sludge and scale build up.

6. Hot water problems due to heat exchanger problems

COLD

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COLD

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Heating System PreparationTurn ON the heating system and identify problem flow areas, cold radiators, or those with cold spots and then switch the heating system OFF.

Make a note of each radiator’s location and its condition (as above).

Carefully record how many turns are required to shut off the radiator and lock shield valves as this will enable the system to be quickly “balanced” once the powerflushing has been completed.

Open all valves fully on both sides of the radiator.

Thermostatic radiator valves must be set to the fully open position. Remove the heads and check that the plunger pin moves freely. If not, the valve may need to be replaced.

Check that the diverter or zone valves are in the fully open position, setting them manually if necessary.

If an anti-gravity/check valve is present, this must be bypassed or bridged to allow the flow reversing action to be used. It may be possible to dis-assemble the anti-gravity valve, and remove the internal components.

Tie up the ball cock and/or turn off the mains water supply.

Drain enough water from the system to empty the Feed & Expansion (F&E) tank. This can be drained into the CalFlush once it is connected.

Vented SystemsThere will be a need to either cap off, or loop together, the expansion and cold feed pipes to avoid filling and overflowing the expansion tank.

The F&E pipes may be capped with push fit fitting end caps or with a temporary standard compression fitting gate valve.

Alternatively looping the feed and expansion pipes together will enable them to be flushed during the cleansing process. This will only be effective where the F&E pipes are not close coupled, or connected via an air separator.

The looping connection may be made with using an off cut of the CalFlush hose, but should incorporate a valve in the loop to close the circuit when flushing individual radiators. Any capping or looping must be removed after the flushing process.

Site SelectionPosition the unit in a room with a suitable drain point and a mains water supply. The cold water supply for a washing machine or dishwasher may be a convenient source of supply.

Set both isolation valves to the closed position.

Run the drain hose and overflow hose to a suitable drain outlet.

Connect the fill up hose to a suitable fresh water supply and open the supply valve. You will be able to control the water flow from the fresh water connector’s isolator valve.

Fill the CalFlush tank with water to a level that is between the Min and Max marker on the tank.

The normal precautions during work on any heating system should be taken and also ensure that a drip tray and/or waterproof groundsheet is used underneath the CalFlush and any surrounding area that is prone to spillage.

Connection to the heating systemConnect the flow and return hoses to the system at the selected point.

PumpUse the two couplings to connect to the circulating pump’s isolating valve.

Close the circulating pump isolating valves, remove the pump and fit the couplings. Only open the isolating valves once the CalFlush is connected.

RadiatorAcross the “tails” to a radiator (after having drained and disconnected this radiator) using appropriate ½” or ¾” BSP female adaptors to connect to the valve bodies.

The radiator valves should be closed to isolate the flushing pump from the system until powerflushing has commenced.

CalFlush-Professional Guidance

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Combination Boiler SystemsThe above connection method is generally used when powerflushing a system with a combination boiler, when the system circulator pump is located in the boiler casing, and is difficult to access.

Flow and return connectors (Boiler)Across the flow and return connections at the boiler isolating the boiler itself.

Across cold feed and expansion pipesBy connecting across the cold feed and expansion pipes where accessible, but not adjacent to each other in the same pipe run. Remember to isolate the water supply to the F&E tank prior to fitting.

Initial flushing procedureInitially, use the CalFlush to loosen the silt and debris in the contaminated water supply. This will remove much of the debris and sludge at an early stage and the chemical from the Calmag Powerflush pack can then work specifically to disturb, loosen, and dissolve more stubborn accumulations of contaminants.

Additional advice relating to combination boiler systemsDuring powerflushing, there is no circulation through the secondary heat exchanger of combination boilers.

To minimise the possibility of debris being pushed into the secondary heat exchanger circuit, close the boiler isolation valves during this first stage of the powerflushing process.

Completed PowerFlushAfter the powerflushing has been completed switch off the unit and unplug it from the power supply.

Disconnect all hoses from the CalFlush and the system.

Empty the CalFlush tank of any remaining water. Note that if the system is vented, the residual water may be poured into a bucket and added to the F&E tank after this has been cleaned.

Reinstating the systemReconnect any removed radiator or disconnected boiler/pump. Reset the radiator balance valves to the original settings.

Remove any temporary isolating valves or caps on the expansion and cold feed pipes, and restore the non-return valves to their normal operation, if necessary. The F&E tank should be thoroughly cleaned and disinfected before placing into service.

Existing debris is often mobilised by alterations to the system/piping and the increased efficiency of the new boiler, and may then accumulate in the boiler heat exchanger, causing noisy operation, reduced efficiency and, in extreme circumstances, failure of the boiler. The high efficiency and compactness of modern boilers, developed to minimise fuel costs and pollution, means that they are more susceptible to problems caused by debris in the system water.

The CalFlush units are designed to powerflush heating systems with minimal dismantling, by circulating water and flushing

chemicals at high velocity, and then purging the dirty water from the system with a high flow of fresh, clean water.Radiators may be individually flushed without removal from the system.

The CalFlush units are purpose designed domestic central heating flushing unit and comes with a fully illustrated operators Instruction Manual. The units utilise a mechanical method of combining high flow and low pressure together with suitable chemical cleansers in order to clean dirty, problematic wet central heating systems.

Hints & TipsWhen flushing an open vented system which has discoloured water in the feed and expansion cistern, it is often a useful exercise to replace the T at the neutral point, ie, the point at which the cold feed and expansion pipe joins the system. The pipework at this point is often restricted by hard deposits of magnetite that extend the flushing time required.

It can be an advantage to join the open vent and cold feed to allow thorough cleaning of these pipes. If this method is used to isolate the open vent and cold feed, a valve should be fitted to prevent flow during the primary and secondary flush on the radiators.

Before recommissioning an open vented system, the feed and expansion cistern should be thoroughly cleaned.

If during flushing, difficulty is experienced in removing cold spots from a large or double panelled radiator, effective results can usually be achieved by injecting air into the top, causing turbulence.

For safety reasons, the water temperature during flushing should not exceed the designated temperature; this is both to avoid damage to the equipment and accidental scalding of the operating personnel.

When using a CalFlush indoors, the use of a bund is strongly recommended to control spillage. During the flushing process, it is possible, when removing heavy sludge, to uncover small holes in radiators. The use of waterproof sheeting under the radiator being flushed will restrict the chance of water damage should this occur.

Always check the condition of the circulator before reinstalling it. Always check the condition of the CalFlush connection hoses and fittings before and after use.

The hose that is supplied with the unit may on initial fitting be tight against the brass connections. To combat this it may be beneficial to warm the ends of the hose in warm water to make the connection easier as the hose becomes more pliable.

Description& Background

For best results use the Calmag range of chemicals

Features and Benefits• COMPACT - Only 720mm high

• LIGHTWEIGHT - 15kg empty

• EASY TO USE - fully easy-to-understand - no need for external training session.

• SAVE TIME AND MONEY• SIMPLE & QUICK TO CONNECT

TO A HEATING SYSTEM - All fittings and hoses included

• 30M OF DUMP HOSE - for all applications

• PORTABLE - built in carry handle

• LARGE TANK CAPACITY - 24 litres

• COMPATIBLE WITH ALL APPROVED CHEMICALS

• IDEAL FOR CRITICAL APPLICATIONS REQUIRING HIGH EFFICIENCY PUMPS

• POWERFUL ACID PROOF FLUSHING PUMP - 0.45Hp and IP54 rated

• 15M HEAD (UP TO 20/30 RADIATORS) PERFORMANCE

• ONE VISIT REQUIRED TO FLUSH ENTIRE SYSTEM

• FLOW REVERSER - dump facility

• OPTIMUM FLOW RATE FOR DOMESTIC PROPERTIES - 30 litres per minute

• WET TESTED PRIOR TO DESPATCH

STANDARD POWERFLUSH UNIT

Product code:CHEM-PF-CALFLUSH

Two Models To Choose From...

Product Name Calmag CalFlushHeight 720mm

Diameter 420mm

Weight Empty 15kg

Weight Working 45kg

Motor rating 0.45Hp

Full load current 330 W

Input power 230V – 50Hz

Fuse rating 13 Amps

Cable length 2.5 metres

Power connection 13 Amp plug BS1363

Motor insulation / RPM IP 54 / 2800

Inlet Connection ¾” male

Drain Connection ¾” male

Recirculation connections ¾” male

Max inlet pressure 6 bar

Max drain pressure 1.2 bar

Max recirculation pressure 1.3 bar

Working recirculation pressure 1.3 bar

Max drain flow 50 lpm

Max recirculation flow 50 lpm

Typical working recirculation flow 44 lpm

Max temperature recirculating liquid 50ºC

1 x 30 metres reinforced hose x ½” to be used for water inlet and dump.

2 x 2 metres flow & return hose - reinforced2 x ½” male - 15mm compression brass fittings4 x ¾” male brass hosetails1 x overflow cap1 x filling cap6 x jubilee clips

CALFLUSH UNIT INCLUDES THE FOLLOWING:-

Example of hoses and parts included in the kit.(All parts not shown)

TechnicalSpecifications

1. Feed and expansion cistern2. Hot water storage vessel3. Circulating pump

4. Bypass5. Boiler6. Closed circuit central heating system

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Typical InstallationPoints Within a System

Features and Benefits

• EXTREMELY PORTABLE - Integral wheels and fully supported handle

• EASY TO USE - fully easy-to-understand - no need for external training session.

• SAVE TIME AND MONEY• SIMPLE & QUICK TO CONNECT

TO A HEATING SYSTEM - All fittings and hoses included

• 30M OF DUMP HOSE• POWERFUL PUMP - 0.75Hp

• COMPATIBLE WITH ALL APPROVED CHEMICALS

• HIGH FLOW RATE CAPABILITY - 150 litres per minute

• 22M HEAD (UP TO 40 RADIATORS) PERFORMANCE

• EXTRA TANK CAPACITY - 40 litres

• VERTICLE AXIS PUMP - optimum performance

• FLOW REVERSER - optimum performance to remove debris & dump facility

• IDEAL FOR LARGER DOMESTIC SYSTEMS

• SUITABLE FOR SMALL COMMERCIAL SYSTEMS

• WET TESTED PRIOR TO DESPATCH Product code:CHEM-PF-CALFLUSH-MAX

POWERFLUSH MAX UNIT

Two Models To Choose From...

Product Name Calmag CalFlush MaxHeight 1000mmDiameter 460mmWeight Empty 26kgWeight Working 66kgMotor rating 0.75HpFull load current 560 WInput power 230V – 50HzFuse rating 13 AmpsCable length 2.5 metresPower connection 13 Amp plug BS1363Motor insulation / RPM IP54 / 2800Inlet Connection ¾” maleDrain Connection ¾” maleRecirculation connections 1” maleMax inlet pressure 6 barMax drain pressure 1.7 barMax recirculation pressure 1.8 barWorking recirculation pressure 1.8 barMax drain flow 150 lpmMax recirculation flow 150 lpmTypical working recirculation flow 102 lpmMax temperature recirculating liquid 50ºC

CALFLUSH MAX UNIT INCLUDES THE FOLLOWING:-1 x 30 metres reinforced hose x ½” to be used

for water inlet and dump.2 x 2.5 metres flow & return hose - reinforced2 x 1” flow & return fittings2 x ¾” fill & dump fittings2 x 1”-¾” male reducers2 x ¾”-22mm pushfit fittings4 x 1” male brass hosetails2 x ¾” male brass hosetails1 x overflow cap1 x filling cap6 x jubilee clips

Example of hoses and parts included in the kit.(All parts not shown)

TechnicalSpecifications

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BENEFITCALFLUSH MAX can deal with 22 metre / 66 feet head or up to 4 building storeys high

1. Feed and expansion cistern2. Hot water storage vessel3. Circulating pump4. Bypass

5. Boiler6. Closed circuit central heating system

Typical InstallationPoints Within a System

The CalFlush and CalFlush Max units have been designed to give a long service life with minimal maintenance. However a few simple tasks need to be undertaken after every clean or periodically to ensure that the units remain in top condition and continues to deliver outstanding performance.

1. MAGNETITE REMOVAL UNITS.

It has been a misconception that these units are to be used instead of traditional powerflushing units – THIS IS NOT TRUE.

Although these particular units can be as a method when working in conjunction with another process it has been substantiated by the ASA (Advertising Standards Authority) in 2011 that these units DO NOT produce “more effective power-flushing results” and also DO NOT “increase profits for installers” as it was not proved to save time.

As a reputable company that offers the full product range, we strongly recommend that to perform a consistent flushing process, we state that a powerflush pump process be used and also consider that a magnetite removal unit can be used as part of this process – but not instead of the process.

Powerflushing is a process which moves water around a system as quickly as possible to agitate and remove any debris to an area where it can be discharged safely.

Please refer to www.asa.org.uk for the full report.

2. ARTIFICIALLY SOFTENED WATER.

It is generally accepted that artificially softened water will be slightly more corrosive than naturally softened water within central heating systems, and through tests and resultant water analysis, has seen to increase the corrosion rate.

Whist artificially softened water is beneficial within the domestic hot water system to protect showers, taps, baths, etc, our recommendation is that the central heating system should be filled with mains water through the bypass if a water softener is installed, wherever possible.

Please refer to British Standards and also the WRAS guidelines for the installation of water softeners.

And Finally...Two areas that we are constantly asked are in regards to magnetite removal units and artificially softened water – here are our results:-

Routine The connection hoses and mains power flex should be periodically examined for signs of abrasion or wear and replaced if necessary.

Extended warranties are available to cover for accidental damage. Please call for further information.

Post useAfter each time the CalFlush or CalFlush Max unit is used it should be thoroughly cleaned to remove deposits flushed out from the heating circuit that have accumulated in the sludge trap at the front of the cleaning solution tank.

CalFlushMaintenance

Scale inhibitorsWater softeningWater filtrationWater chillersUV disinfection

Reverse osmosisCommercial products

Calmag Yorkshire Ltd Tel: 01535 210320Fax: 01535 210321

E mail: sales@calmagltd.comWeb: www.calmagltd.com

Due to Calmag’s commitment to new product development the photographs contained within these instructions may depict earlier product models - Calmag reserve the right to alter specification without prior notification - please contact Calmag technical services on 01535 210320 (option 2)

Certificate No. 5791

Calming troubled waters