Magnetite and sludge in heating water led to heating circuits of different temperatures in a single-family house in Esslingen near Stuttgart. On behalf of the specialist trade, Orben Service was able to treat the heating water directly on site at the customer's site in accordance with VDI 2035 using a mobile system in just a few hours.
The heating system in the old and new part of the building consists of two underfloor heating circuits and is supplied by a gas heating system. The customer called his specialist technician because his heating system on the ground floor of the new building was no longer getting really warm. When black “soup” leaked out of the corroded radiator when changing a bathroom heater, it was clear: The system with 1200 l of water content was silted up and must either be refilled or the existing heating water must be treated. The black color of the heating water also indicated a high magnetite content. The assumption: The magnetic sludge had deposited as a layer on the pipe walls of the floor heating systems, massively restricted heat transfer and changed the pressure conditions in the system.
Because the specialist craftsman himself had no capacity at the moment, the Orben service was used. It comprises a complete service for treating heating water using a bypass process. The service is carried out in three stages via wholesalers and relieves the workload of specialist trade. It is available in over eight branches across Germany and is suitable for systems of all sizes. Even large heating systems with up to 120,000 liters per hour can be supplied. Experienced technicians take care of the entire process, including water analysis, action plan and documentation. The work is carried out in accordance with DIN EN 14336 and VDI 2035. Specialized companies benefit from this service in particular during peak orders or staff shortages.
On site, the heating water was first visually checked and the total hardness, pH value and conductivity were measured. This is an important step because: Heating water treatment in accordance with VDI 2035 is a prerequisite for all manufacturers for a warranty, such as on heat generators, heat exchangers and circulation pumps. If the heating water does not meet the VDI values, the warranty may expire. Clean heating water thus protects specialist tradesmen from liability risks and secures warranty claims.
A pH of 9.5, a conductivity of 107 µS/cm and a total hardness of 3.5 °dH were outside the requirements of VDI 2035, which requires, among other things, a conductivity of < 100 µS, a pH of 8.2 to 9.0 for aluminum components in the system and 8.2 to 10.0 for other materials and a maximum total hardness of the water when operating with low salt levels of <0.3 °dH.
The treatment was carried out using the bypass process while the plant was running with the “Thermostil mobil 4000” from Orben. Since leak-proof special connectors were used, no craftsman needed to be on site during ongoing preparation — three times the circulation rate of the total volume, with a circulation of 560 l/h each, was completely automatic within six hours. To ensure complete documentation of the amount of heating water being recirculated, the water meter was photographed on Thermostil before and after desalination. All results of the initial measurement were documented in the appendix.
First, all actuators, radiators and thermostats were fully opened so that all circuits could flow completely. The Thermostil Mobil was then connected in the boiler room via two KFE taps via quick connectors; to remove water from the return line and to feed in the then treated heating water back to the flow. Whereby the hose for the flow was only connected after venting. This was done simply by starting the pump until a little heating water instead of air came out of the hose for the flow.
The shut-off valves on Thermostil have now been opened. The maximum operating pressure is 6 bar. The circulation is supported by the integrated heating circulation pump (12 mWs). The heating water from the return line now flows through the integrated magnetic flow filter and the fine filter in the device. With this magnetite and sludge removal, even the smallest particles of 1 μm are captured and removed from the heating water. (For comparison, the diameter of a human hair is approx. 50 µm.)
For full desalination in accordance with VDI 2035, the heating water flows over the high-performance resin Thermion2035 pH-Conform. It is in a robust stainless steel cartridge (23 l), which is equipped with an LED conductivity indicator to control an imminent change. With its high desalination capacity, this mixed-bed resin produces VDI 2035 compliant water and thus protects against corrosion. The pH value is adjusted automatically without the addition of chemicals. LEDs on the top cover of the resin cartridge announce the imminent resin change via a traffic light system.
Best financial statements documented
The pH was reduced from 9.5 to 8.5 and was therefore well within the prescribed range again (VDI requirement between 8.2 and 10.0). The residual hardness level that has now been achieved also speaks for trouble-free operation in the future. In addition to the current status of the water meter, the system book now also contains optimal and VDI-compliant measurement values. The documentation of the values ensures that the manufacturers' warranty conditions are met. The entire heating water treatment was carried out by Orben Service - on behalf of the specialist craftsman on site at the customer's premises.
More information: www.orben-heizwasser.de
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