ScaMag

Boiler Water Treatment

User Operation and Maintenance Manual

In Tank Emitter Configuration
Model No: DAC-Customized
V 1.0-April 2014

2014 ECOSPEC GLOBAL TECHNOLOGY PTE LTD

PRINTED IN SINGAPORE
Contents:

1. Introduction ................................................................................................................. 3
1.1 Scale Control ............................................................................................................. 3
1.2 Corrosion Control ..................................................................................................... 3
2. Typical Installations .................................................................................................... 5
3. Product Specifications ................................................................................................. 6
3.1 DAC-Customized Power Unit .................................................................................. 6
3.2 Standard In-Tank Emitter/Emitter Receiver Specifications ..................................... 8
4. Operation and Maintenance ........................................................................................ 9
1.1 System operation .................................................................................................. 9
4.2 Water Care and Conditions ..................................................................................... 10
4.3 Maintenance ............................................................................................................ 12
4.4 Troubleshooting ...................................................................................................... 13
4.5 Spare Part list .......................................................................................................... 13
5. Testing and Commissioning....................................................................................... 14
6. Performance Monitoring ........................................................................................... 14

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 1. Introduction

1. Introduction

DAC-Customized is a highly effective, low power consumption system encompassing

ultra low frequency (ULF) electromagnetic pulses in the form of ionic current to treat
boiler feed water without the use of chemicals. The ULF ScaMag system includes the
ULF generator and In-tank Emitter that are designed to control scale and corrosion right
from the start of the feed water source. In addition, the system also ensures full corrosion
protection to the metallic feed water tank. Direct and ease of installation without any
down time to the boiler operation has given it a viable option for boiler water treatment.

1.1 Scale Control

ScaMag consists of an ULF (ultra low frequency) electromagnetic pulse generator
and an In-tank Emitter unit employed to treat boiler water. Boiler feed water receives
the treatment in-situ when the In-tank Emitter produce ionic current through the feed
water within the feed water tank.

Boiler feed water is treated by ScaMag ULF (ultra Low Frequency) electromagnetic
pulses, its calcium ions will either remain in dissolved state in the water or
precipitates as fine powdery Aragonite in water. Hence, hard scale Calcite calcium
carbonate precipitation on the tube wall will be effectively controlled.

With ScaMag treatment, existing scale will gradually dissolve back into the water
and descaling will take place. This results in a cleaner boiler water system and
effective in controlling under deposit corrosion.

1.2 Corrosion Control

Corrosion in boiler is controlled by the ScaMag induced magnetite formation. It is
an inherent feature of ScaMag which generates a specific spectrum of ULF wave
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 which promote the formation of magnetite protective layer for effective corrosion
control.

With the induced magnetite formation by ScaMag ULF excitation, protective

magnetite (Fe3O4) is formed on the steel surface instead of the common non-
protective red rust (Fe2O3). Protective magnetite is self repairing and inhibits further
corrosion.

Corrosion activities in boiler water are caused by Fe ions production and its severity
is dependent on the Fe ions concentration in the water. ScaMag can effectively
control the corrosion activities in the boiler water system and it is able to control the
Fe ions level to below 5 ppm.

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 2. Typical Installations

The typical installation diagram for boiler water treatment application is shown in Figure
1 below. An In-tank Emitter (metal part) is to be submerged in the feed water and
aligned to the center of the tank to ensure even distribution of ionic potential. The Emitter
Receiver is to be mounted above the water line, i.e. either by welding or bolting to the
feed water tank. Meanwhile, the power unit should be installed as close as possible to the
feed water tank, and it is advisable to be installed in the zone where it is less affected by
heat and direct exposed to sunlight, rain etc.

Figure 1: ScaMag In-Tank Emitter configuration for boiler water treatment

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 3. Product Specifications

3.1 DAC-Customized Power Unit

Figure 2: Dimensional Drawing of ScaMag (DAC-Customized)

DAC-Customized Specifications
Model ScaMag DAC-Customized
Circuit control CPU
Casing material Mild Steel Enclosure
Service 6Ton/hr Boiler
Power 4. Inductor Coil Specifications
AC80V-260V/60Hz-50Hz,750W
Weight 8kg
Size 600mm x400mm x 250mm (W x H x D)

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Figure 3: Interior of power unit, with wires connection to emitter (in red) and emitter
receiver (in blue)

Above showing the interior of the power unit with various components but the key one
includes the ULF driver card, a power supply, and a DC controller. ScaMag is a two wire
system where the red line indicate the connection point to the In-Tank Emitter and the
blue line to the Emitter Receiver. The detailed design of the emitters can refer to the
followng Figure 4 (subject to change depends on site condition and tank size).

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3.2 Standard In-Tank Emitter/Emitter Receiver Specifications

Figure 4: Dimensional drawings of In-tank Emitter (left) and Emitter Receiver (right).

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 6. Troubleshooting

4. Operation and Maintenance

1.1 System operation

With refer to Figure 2, the selector main switch regulates the ON, OFF mode of the
system. During the ON mode, Ultra Low Frequency (ULF) electromagnetic pulses will
be activated and system is shut off when the switch is turned to OFF mode. The
operating sequence are as follow:

ON Sequence

1. Turn selector switch to ON mode

2. Ensure that Incoming LED is on with green light (with main breaker on)
3. Ensure that Power On LED is on with green light
4. Ensure that Driver LED is on with green light

OFF Sequence

1. Turn selector switch to OFF mode

2. Ensure that Incoming LED is on (with main breaker on)
3. Ensure that Power On LED is off
4. Ensure that Driver LED is off

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4.2 Water Care and Conditions

BacComber non-chemical water treatment program for boilers system has proven to be
effectively against scaling and corrosion. A water analysis program is essential with
BacComber water treatment and should be carried out in line with the use of the system.
Understanding the water conditions before and after the use of the BacComber system
helps in the assessment of the treatment effects. In addition, regular monitoring of the
water conditions after the use of the BacComber treatment system helps to maintain good
water quality for optimum effects.

After installation of the BacComber system, it is preferred that the boiler feed water and
boiler water analysis to be conducted every other day for the first two weeks
(recommended) until the results reflect a relative stable water quality. Then on, followed
by weekly for three months and then monthly water analysis thereafter should be
conducted, and the water quality should be monitored closely concurrently. Pls refer to
appendix B. Post Commissioning Performance and Water Monitoring Data Log Sheet to
assist in up-keeping this record.

The parameters that need to be routinely monitored for BacComber boiler treatment are:
pH, Conductivity or Total Dissolved Solid (TDS), Fe ion, total hardness and alkalinity for
both boiler feed water and boiler water.

The interpretation of the water test results is illustrated in the following table.

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 Parameters Unit Desired Range Remarks
and Limit for
Boiler Water

Since boiler is a closed loop system,

during BacComber treatment, pH will go
pH N.A. 7-12 up to around 10. However, a higher pH
is favorable for magnetite formation to
reduce the corrosion rate.
Conductivity s/cm <5000 To ensure the treatment result.
Conductivity and TDS should be
maintained. To maintain a proper
TDS ppm <2500 conductivity and TDS, regular blow
down is a must. Usually at an interval of
3-4 hours and last for 1-2 minutes.
The sample collection method is very
essential for boiler water analysis result.
Before sampling, water must be flushed
Fe ppm <5
for a while until water become clear to
avoid the accumulated deposits affecting
the testing results.
Total Hardess Total hardness and total alkalinity used
ppm <600
as CaCO3 for evaluating the treatment
Total performance. An indicator for the
Alkalinity as ppm <500 tendency of scale formation
CaCO3

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4.3 Maintenance
Minimal maintenance is required for ScaMag Boiler Water Treatment system.
Nonetheless, to ensure the proper functioning of the system, following maintenance
routine should be carried out periodically as such:

ScaMag system should be kept on at all time to ensure effective water treatment

Ensure that all LEDs on the power unit have its green indication light constantly
on

During system intervals, check the current reading against what was recorded at
the beginning of operation. Ensure that the current readings have no extreme
deviation. Please refer to readings as recorded in the post commissioning
performance and water monitoring data log sheet in Appendix B.

Check any damages or corrosion on the electrical components inside the power
unit.

Regular blow down of the feed and boiler water to ensure the water parameters
are within control limit and perform within the capability of the system.

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4.4 Troubleshooting
Troubleshooting Tips:

When testing the control panel, emitters should be connected (unless otherwise
noted). If either end is not connected, the results may be inaccurate.

Always keep a small jumper wire or small test-pen in your toolbox for
troubleshooting.

Unless otherwise noted, ALWAYS remove power from the machine before testing
any wires to avoid electrical shock.

If you require assistance in troubleshooting, please have the serial number and a
description of the problem available before calling.

If the Power Unit does not function:

1. There may be setup errors or shipping damage. Review all the previous sections.
2. Check the power supply and make sure the power switch is on
3. Perform a quick check to see if there are obstructions preventing the ScaMag
from functioning properly.

4.5 Spare Part list

No. Parts Description

1 Power Supply Unit

2 DC Controller

3 ULF Driver card

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 5. Testing and Commissioning
Refer to appendix A.

6. Performance Monitoring
Refer to appendix B.

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 Ecospec Global Technology Pte Ltd
60 Admiralty Road West
Singapore 759956
Tel: (65) 6752 2222 Fax: (65) 6758 2657
www.ecospec.com

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