EN Demineralised heating water perfect for every system PUROTAP easy Installation Function Operation Service fast efficient safe Minerals and salts in technical water circulations lead to corrosion and mineral deposits. PUROTAP filters aggressive materials out of the water and enables trouble-free operation. www.elysator.com
Combat lime precipitation Content 3 EN 4 Combat corrosion 5 According to current standards 5 The function 6 Connection variations system fill-up 7 Connection variations system cleaning 8 Operating the meter 9 Apparatus components 10 Change ion exchanger resin 11 Empty water 13 Repair malfunction 14 Updates may be made without notice. Web version supercedes print version. www.elysator.com
EN 4 Combat lime precipitation in the boiler and heat exchanger Completely desalinated water no longer contains any substances that can damage or settle in boilers and heat exchangers. The following table shows the amount of lime that accumulates as a result of filling the heating system once with untreated water. Total hardness fh fh 50 45 40 35 30 25 20 15 10 5 3 Amount of lime in 1 m of fill-up water dh 28 25 22 20 17 14 11 8 6 3 Total hardness dh Overheating, stress crack 0 100 g 200 g 300 g 400 g 500 g Amount of dissolved calcium carbonate (CaCO 3 ) According to many manufacturer specifications and technical guidelines, fillup water must normally be desalinated (demineralised) for heating systems. Practice has shown that modern devices such as wall-mounted gas boilers, heat pumps and solar systems are damaged by lime precipitation even at lower water hardness levels. The larger the system capacity (e.g. storage tanks), the more lime is introduced with the fill-up water. With a hardness of 17 dh (and/or 30 fh), 300g of lime accumulates per m 3 of water. This is still approx. 100 g for a single family dwelling with 350 l of system water content. This amount is more than enough to damage a modern highcapacity heat exchanger. Lime precipitation in the boiler Better than softened water By replacing the calcium and magnesium ions with sodium ions during softening, the hardness components are removed from the water but the salt content remains high and unchanged. This is a disadvantage for modern systems with different metals in the system. If guidelines recommend water softening, then this can be interpreted in such a way that more weight is attributed to the prevention of lime scale at a specific hardness than to the prevention of corrosion. This compromise is accepted because softened water is probably available locally in regions with critically high water hardness, whereas a complete desalination system is not. There are no compromises with use of desalinated (demineralised) water when it comes to combating mineral deposits.
5 EN Combat corrosion Since corrosion processes in closed heating systems mainly involve electrochemical reactions, the electrical conductivity of the water plays a direct role in the rate of these reactions. The salt content of the water determines the electrical conductivity. According to VDI guideline 2035, increasing amounts of oxygen are tolerated with reducing water salt content. When ions are present that can take over the transporting of electrical currents in the water, the formation of galvanised elements that can lead to local corrosion (corrosion elements) is practically impossible. Desalination also removes all neutral salts such as chloride, sulfate and nitrate that are known for causing corrosion above a certain concentration and in a specific interaction. Corrosion pittings for high levels of salt According to current standards Authority: Guideline/Standard: Citation: VDI (German Associations of Engineers) 2035, Prevention of damage in water heating installations, corrosion in the water system. [Sheet 2, Para. 8.5.] "Increasing amounts of oxygen are tolerated with reducing water salt content. When ions are present that can take over the transporting of electrical currents in the water, the formation of galvanised elements that can lead to local corrosion (corrosion elements) is practically impossible." [Sheet 2, Para. 8.5.] When filling up larger warm water heating systems for the first time, it is recommended that desalinated water is used [...] Corrosion rate Salinity in the water DIN German Institute for Standardisation SWKI Swiss Society of Heating and Air Conditioning Engineers DIN 50930 Corrosion of metallic materials under corrosion load by water inside of tubes, tanks and apparatus BT102-01, Water quality for building services engineering systems [Part 3, Para. 7.2] Chloride and sulfate ions stimulate the anodic partial reaction of metal corrosion. The corrosion probability for local corrosion can be reduced through selective anion exchange. [Para. 4 ff] "Fill-up water and make-up water must be desalinated." [d] "Demineralisation (complete desalination) is the best technical solution for water with high chloride or sulfate content." It has always been clear among experts that completely desalinated water is perfectly suitable for the fill-up water in heating systems and thus, the service life of all components is extended. Today this technology is very user-friendly and affordable that it is ideal for practical application.
6 EN The function Heating and cooling systems use water as a medium for heat transfer. The water circulates from where the warm water is generated to the user and back. Even if the system always re-uses the same water, lime and aggressive materials enter the closed water system when first filling the system, which can damage modern components. The filling apparatus filters lime and aggressive dissolved substances such as sulfate, nitrate and chloride out of the fill-up water. The device operates on the basis of a mixed bed ion exchanger and provides demineralised water that has been completely desalinated. Thus, damage caused by lime and corrosion can be effectively prevented in the heating system. The filling apparatus is equipped with precise meters for monitoring pure water production in terms of quality and quantity. This method does not release any chemical additives into the water. The device operates without an external power supply. If the ion exchange capacity is exhausted, then the ion exchange resin can be easily replaced and disposed of with the household waste. Protective measures: Only trained personnel should use the filling apparatus. Operating specifications must be adhered to according to this manual. Local guidelines are to be followed for the connection between sanitary and heating systems. The device already has a returnvalve. In the DIN EN 1717 (Germany) field of application, a pipe disconnector must also be installed before the fill-up station. The system is not suitable for unmonitored, permanent connection under pressure. The valves in the input and output are to be kept closed and only to be opened for the duration of the system filling. Even demineralised water contains dissolved gasses, including oxygen and carbon dioxide that can cause the beginning of a corrosion process. The gases are purged by heating the water, therefore we recommend carrying out a heating test run for the system as soon as possible after fill-up. According to the latest standards Leading boiler manufacturers and component suppliers approve and recommend the procedure for purging make-up water via the ion exchanger. The demineralised make-up water as a result of desalination also fulfills the requirements for heater fill-up water quality according to VDI guideline 2035 (Association of German Engineers), the SWKI guideline BT 102-01 (Swiss Heating and Air Conditioning Engineers) and the Ö-Norm H5195.
7 EN Connection variations system fill-up This connection variation is suitable for directly filling heaters with demineralised water. This connection variety is not suitable for area heating systems that can only be deaerated through purging. The delivery rate of the ion exchanger is not sufficient enough to purge air from a horizontal line. In these cases, we recommend fill-up with untreated water and subsequently demineralise via a cleaning system (see following page). The inlet for untreated water is under the connection of the apparatus valve, the outlet for the demineralised water for the heating system is on top on the other side of the safety sieve. The apparatus contains a non-return valve. When the connections are turned, the untreated water cannot flow through the apparatus. In the DIN EN 1717 (Germany) field of application, a pipe disconnector must also be installed before the fill-up station. Follow the guidelines from the water supply company. PUROTAP contains mechanisms for automatic stop. If the system fill-up is not constantly monitored, then a pressure-reducing valve needs to be installed so that the heating system is not damaged by over pressure at the end of fill-up. PUROTAP easy may only be under pressure for the duration of filling. Temp. max. 60 C, pressure max. 6 bar. Flow Return Cold water Outlet Inlet Boiler Drain and feed cock
8 EN Connection variations system cleaning Directly filling via the ion exchanger is not suitable for area heating systems that can only be deaerated through purging. The delivery rate is not sufficient enough to purge air from a horizontal line. In these cases, we recommend fill-up with untreated water and subsequently demineralise via a cleaning system. This procedure is also suitable for demineralising systems with too much salt content according to the boiler manufacturer's specifications or guidelines later. Thereby, the ion exchanger is integrated into the heating system circulation with the help of a separate pump (e.g. jet pump, impeller pump, centrifugal pump) and two reinforced hoses. Hereby, it is of less importance which adapter is used; instead, it is more important that circulation pumps are operating and all valves are open and a good mixture of the system water is possible. The apparatus meter indicates if the resin is exhausted. The system water demineralisation progress can only be determined during cleaning with a second meter and via sampling. The apparatus contains a non-return valve. When the connections are turned, the untreated water cannot flow through the apparatus. PUROTAP easy is to be connected to the pressure side of the auxiliary pump. If this cleaning variation is conducted during heating operation, then the apparatus temperature may only reach a maximum of 60 C for a short time. The apparatus is to be connected to the return line with the lowest temperature possible. Hoses that are sufficiently pressure and temperature resistant are to be used (reinforced hoses). The ion exchanger may not be under pressure without monitoring. Outlet Inlet Return Flow Return Flow Reinforced hose pressure side M a i n d i s t r i b u t i o n Pump
9 EN Operating the combined meter The combined meter is battery-operated. It measures the flow rate in l/min, the total volume in litres and the concentration of dissolved minerals, either in microsiemens or TDS. In addition, a limit can be set for the maximum concentration of minerals tolerated in the demineralised water (appliance outlet). The limit and overall total can both be reset. Display: Limit Automatic quality monitor Flow rate Limit warning signal Total litres treated Recommended limit value: 33 TDS/50 µs, if this is exceeded then the resin needs to be replaced Keys: Set limit for warning Select either TDS/µS ON/OFF Reset meter 1 2 Each time you touch this key, the boundary value is raised by 6/7 TDS or by 10 µs/cm. Holding down the key for 3 seconds resets the boundary value to zero. Programming the boundary value serves as a warning as to when the ion exchanger resin is exhausted. This key can be used to switch at any time between the TDS unit of measurement (Total Dissolved Solids) and electrical conductivity. Both are used to measure the concentration of dissolved minerals in the water. Most European component manufacturers use the µs/cm unit of measurement (microsiemens). The water hardness at the outlet of the refill appliance can be calculated using the following rule of thumb: 1 fh equals approx. 20 µs/cm; 1 dh equals approx. 35 µs/cm. 3 If the ON key is pressed once, the water quality is measured for 10 seconds and compared to the set limit. The measured value is shown. If it is above the limit, the LED glows red; if it is below, the LED glows green while the measurement is being taken. If required, the measurement can be repeated manually. Auto mode: If the ON key is pressed for a second time, the combined meter begins automatic monitoring. The eye symbol appears to indicate that monitoring has been enabled. In auto mode, the meter only takes measurements when water is actually passing over it. If the water draw-off is interrupted, the meter continues to show the last captured value. While water is being drawn off, the combined meter measures the water quality every 40 litres. If the limit is exceeded in two successive measurements, the display continuously flashes red. This indicates that the ion exchange resin is spent and needs replacing. If the ON key is pressed for a third time, the meter exits auto mode. 4 Pressing the reset key for 3 seconds resets the overall total on the meter. This is recommended every time the resin is replaced, as it gives a reference point for the remaining capacity of the ion exchange resin. Changing the batteries Change the batteries when the battery warning symbol appears or the display is faint or blank. Undo the 4 screws on the front and carefully open the device. Change the batteries. 3 x AAA. 3 x AAA
10 EN Apparatus components Calculating the capacity Handle Safety sieve Outlet Measuring computer Inlet Non-return valve Screw head for resin exchange Calculating the capacity Why the capacity calculation? Chrome steel, inline coated load up to 6 bar, 60 C 1. In order to know the amount of resin needed for the demineralisation of the system water. Weight 18 kg. ready for operation 2. In order to know the capacity of a resin fill-up that does not have to be monitored. The capacity (range) of the ion exchanger resin is dependant on water hardness. It can be referred to from the adjacent table, or calculated with the capacity figure of the resin amount. PUROTAP easy resin filling has a capacity of 35 m 3 at 1 fh, and/or 20 m 3 at 1 dh. The number 20 is used for German hardness grades and this is divided by the water hardness in dh. The number 35 is used for French hardness grades and this is divided by the water hardness in fh. The result is the resin capacity in cubic metres of water. Example: with a water hardness of e.g. 20 dh, the capacity range of the resin amounts to exactly 1 m 3 (1,000 l) of demineralised water. fh Capacity 50 45 40 35 30 25 20 15 10 5 35 m 3 à 1 fh 20 m 3 à 1 dh Litres of demineralised (completely desalinated) water per cartridge 0 l 500 l 1'000 l 1'500 l 2'000 l 2 500 l 3 000 l 3'500 l 4 000 l 4 500 l dh 5 000 l 28 25 22 20 17 14 11 8 6 3
11 EN Change ion exchanger resin If the content of dissolved solids in treated water increases over 30 TDS and or 45 µs (approx. 2 fh) according to the meter, then the resin needs to be changed. We first recommend that the water supply is shut-off shortly, shake the cartridge and then slowly turn the water supply back on and fill-up. Thus the remnant capacity can be as exhausted as possible. Even the flow rate restriction is improves the use of the remnant capacity. a) Empty used resin 1. Unscrew the head from the bottle and pull out. 2. Loosen the cap from the drain nipple on the bottom of the bottle. 3. Pull the catch sack for emptying over the resin container. Connect the drain valve (accessories) or the water hose directly on the bottom of the resin container. 4. Shake the resin in the catch sack and rinse the residue resin in the sack with fresh water via the drain valve. Dispose of the used resin with the catch sack with the household rubbish. Fresh water Drain valve (accessories)
12 EN b) Fill with new resin 1. Screw the cap back on the bottom of the resin container for fill-up. 2. Cut the corner of the resin sack open and fill the resin in. Only use original mixed resin. 3. Screw the head back on, check the o-ring and the sealing face for tightness and cleanliness. Check to make sure that the insert prove is secure during each resin change. Check to make sure that the insert prove is secure during each resin change. The resin granulate is to be stored in a moist place and this is the reason why it is delivered in sealed plastic bags. Once the bags are opened, use the resin immediately. The resin can be stored in a cool dark place for up to 12 months. There is the risk of capacity loss and bacteria formation if now correctly stored.
13 EN Empty water In order to reduces the weight of the apparatus during operation-ready status and in order to prevent frost damages in winter, we recommend that the water is emptied after use. 1. Loosen the cap on the bottom of the bottle. Draining contains a fine sieve, so that resin cannot leak out. Check that the fine sieve is correctly installed. 2. Turn PUROTAP easy and let water drain out. 3. Replace cap.
14 EN Repair malfunction The meter display goes off after approx. 10 seconds. The automatic shut-off of the meter serves to conserve the batteries. In manual mode, the ON button much be pressed for each measurement. Alternatively, auto mode can be used (press the ON button two times), then each of the last measuring values are permanently displayed. A display or battery symbol does not appear Change batteries. Loosen screws on the front. 3 x AAA Carefully remove the front of the meter and replace the batteries.
15 EN The flow is weak despite the unrestricted supply line The apparatus has 2 fine sieves for preventing ion exchanger resin from leaking into the heating system. Check the fine sieve in the outlet and on the immersion hose regularly. Plastic - ring pressed in Stainless steel sieve Immersion hose fine sieve The resin appears to be used faster than calculated There probably is not a malfunction, instead the untreated water contains dissolved solids (sulfate, nitrate, chloride) in addition to lime, which are removed and thus reduces the capacity.