Anti-Scale ReactorASR®Technology

an hydrodynamic process with electro-static and galvanic action

Anti-Scale Reactor – the patented physical water conditioner designed to inhibit and remove scale

together with providing corrosion protection

Anti-Scale Reactor is a physical water conditioner that creates an

hydrodynamic process with electro-static and galvanic action. ASR has

been installed in industrial, commercial and domestic applications

throughout the world for over 20 years.

Anti-Scale Reactor features and benefits

• Uniquely inhibits and removes limescale inhard water areas, but also reducescorrosion in both hard and soft water areas

• No annual running costs - operates withoutthe use of chemicals, magnets or electricity

• Savings in energy and maintenance as theunit is self- cleaning and is ‘fit and forget’once installed and earthed correctly

• Maximises heating efficiency

• Extends the operational life of metalpipework and equipment

• Removes the habitat where bacteria growand hence reduces the risk of Legionellacontamination

• Coagulates suspended particles toenhance filtration system efficiency

• Constant water treatment whenever waterflows through the unit

• Low internal flow resistance

• Environmentally friendly

• No mechanical moving parts to be replaced

• Compact, easy to install and retro-fit

• Available in all standard pipe sizes – fromcomplete water systems to single pointprotection

• Proven track record – installed worldwide

reduce andinhibit corrosion

prevent bacteria algae and slime

reduce and inhibitlime scale

improve filtration

ASR the cost effective,

environmentally acceptable

way to...

After treatmentScale particles are unableto adhere to systemsurfaces. Corrosion iscontrolled - further damage is prevented

PTFE dielectricactivators. anti blockingand corrosion proof

Hydrodynamic microjetchamber design.

Zinc anode.Unique dry electricalconnection producingapprox. 1 volt

Before treatmentScale will adhere to thesystem surfaces and corrosionis not controlled

Directionof waterflow

Directionof waterflow

ASR uses a proven method of physical water treatment technology having been refined over the years into the current patented version. It is a powerful and unique device which both inhibits and removes the formation of scale and corrosion when fitted as part of a new building design or retro-fitted into an existing installation

ASR is a Taiwan designed and manufactured product which is environmentally and ecologically friendly.

ASR is providing physical water conditioning around the world in a wide range of applications and varying

water qualities.

ASR consumes no polluting chemicals or energy once installed

ASR generates water turbulence and applies dynamic pressure within it’s structure to force the water through the specially designed multi-channel microjet chambers to maximize the surface area of water treatment for a

given pipe size

As ASR generates its own source of electrical energy, water treatment is continuous whilst there is water flow through the unit. Any variations in water pressure, flow rate, or water hardness are easily handled while

performance levels remain consistently high

The ASR can be used in a range of water conditions, both potable and non-potable. It can also be applied widely to the protection of manufacturing equipment and

within a range of processes

ASR is a ‘fit and forget’ product which is extremely cost effective as there are no ongoing costs of maintenance, power consumption, chemical supplies or parts to

purchase and install

The ASR range is suitable for use in industrial, commercial and domestic applications. Since 1992 it has been installed extensively throughout the UK in schools, hotels, food processing plant, retailer outlets, sports and leisure complexes, local and national government properties and in a wide range of commercial buildings.

Anti-Scale Reactor - the operating principles

LIMESCALE

ASR creates a number of separate effects which combine to produce a physical water conditioner that works effectively over a wide range of conditions and water hardnesses.

ASR, through a unique combination of hydrodynamic action, dielectric charge and a large surface of zinc anode, enables the premature precipitation of calcium carbonate into the water stream by breaking down a significant proportion of the bicarbonates.

HYDRODYNAMIC ACTIONInside each ASR carefully designed hydrodynamic chambers create microjet turbulence and pressure changes as the water passes through. This effect increases the tendency for water to yield prematurely some of the scale with which it is saturated. Sonic effects created in the water by this hydrodynamic action help to keep the inside of ASR free from fouling due to algae or scale.

DIELECTRIC ACTIONASR incorporates a large surface area of PTFE, a dielectric material. When water passes over the surface of the dielectric material, electrical energy is generated. This electrical energy passes harmlessly through the stream of water creating a de-stabilising effect, enabling the premature precipitation of calcium carbonate into the water stream by breaking down a significant proportion of bicarbonates.

ANODIC ACTIONASR also contains a large surface area of zinc, which is bonded to the body of the unit by a unique patented dry connection. This ensures that electrical conductivity is not impaired due to the potential build up of corrosion at the point where the zinc anode meets the body of the unit. The electrolytic cell formed by the zinc and the body allows the slow release of zinc ions into the water stream which act as nuclei for scale formation.

REDUCING EXISTING SCALE AND CORROSIONAs a result of concentrating some of the substances that aredissolved within the water, the water becomes less saturated. This inturn enables the less saturated water to start to dissolve existingscale and rust deposits from the walls of pipes and heatingappliances. Over a period of time historical deposits that have builtup can be flushed from a system.

SCALE AND THE ENVIRONMENTASR is an environmentally sound method for combating hard water scale and corrosion since it uses no power or chemicals and requires no maintenance. It uses the kinetic energy created by the water itself moving through the unit to create the forces and effects to provide the conditioning. Although the zinc is sacrificial as part of

the process the levels are sufficiently small that the unit will continue to operate effectively without the need for component replacement.

Anti-Scale Reactor inhibits and removes limescale

Typical problems of scaling....

...solved with ASR

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▼

CORROSION

THE PROBLEMCorrosion is found in water pipes, water treatmentdevices and various appliances. Corrosion is also aproblem for certain grades of stainless steel and can be of even greater concern for old fashioned, galvanised systems. The cost associated with the refurbishment ofpipes, systems and equipment is substantial.

Corrosion is the destructive attack of a material byreaction with its environment. Most corrosion iselectrochemical in nature hence it follows thatelectrochemical devices and techniques can be used toinhibit the corrosion process.

THE SOLUTIONThe ASR uses a method of action that is electrochemical in nature. The galvanic effects of the special zinc anode offer cathodic protection to pipe-work upstream and

downstream of the ASR. The zinc

Anti-Scale Reactor inhibits and removes corrosion

anode contributes to the precipitating effect onnegatively charged particles. The zinc ions play animportant part in breaking down existing rust andcorrosion deposits through interchange with iron-basedcompounds.

The ASR technology precipitates carbonates from solution, therefore, the water becomes less saturated. It is then slowly able to start dissolving old scale and corrosion encrustation in water systems reducing pressure drops caused by restricted flow and saving

energy in heating systems and appliances.

Once the existing corrosion is cleared, the unique internationally patented design of the ASR prevents

further attack in metal systems by forming a

passive layer of magnetite ( Fe3O4 ) on the systemssurface.

KIST - INDEPENDENT CORROSION REPORTKIST, the Korean Institute for Science and Technology carried out work on the changes that took place to the surface of iron pipe within a heating pipeline as a consequence of the installation of a ASR for a period of

six months.

Prior to the installation the surface of the pipe wasexamined under an electron microscope where theydiscovered the surface was coated in irregular shaped iron oxide (rust). Once the ASR had been installed and operated for six months the pipe was re-examined and the rust had changed into regular

shaped Magnetite.

The magnetite was providing a protective coating tothe inside of the iron pipe-work reducingdiscolouration of the water. Used over an extendedperiod of time it will prolong the operational life ofsystems and pipe-work.

BACTERIA, ALGAE AND SLIMEThe ASR technology combines several effects, which help to prevent the environment in which bacteria, algae and slime thrive. The most obvious way in which ASR creates hygienic conditions is by removing hard water scale and corrosion from pipes and heating surfaces. It is a well-known fact that scale provides an excellent breeding habitat for bacteria and the creation of bio-films. Clean smooth surfaces prevent habitats from being

established in water systems.

The two effects outlined below are little known, but unique to the patented design of the ASR.

The first effect results from the use of dielectric material(PTFE) in specially designed passages and microjetchambers create capacitive effects due to the generation of ‘static charge’ on the boundary layer of the PTFE.These very large surface areas of PTFE have the effect of neutralizing charged colloidal particles, that until thatpoint are kept in suspension as extremely small particlesbecause they carry a charge. By neutralising thesecharges, they come out of suspension and flocculate toform larger particles.

The second effect is that the presence of a large surfacearea of zinc anode causes the release of minute amountsof zinc together with oxides of zinc formed at thecathode (in this case metal pipes and vessels). Thesealso act as coagulants as well as acting as nuclei toinitiate the formation of large particles.

The creation of floc has two key benefits that contributeto preventing the growth of bacteria. Firstly the flocabsorbs nutrients within the water that are vital forbacteria to thrive and multiply. Secondly by forminglarger particles filtration can be used to remove theparticles from the water altogether.

ASR has many applications including:

• central heating systems and chiller units

• hot/cold water systems

• protection of production processesIt can also be used to pre-treat irrigation water in ponds and reservoirs to avoid contamination by algae and slimewhere nutrients are needed to propagate.

ASR IMPROVES FILTRATION ASR’s principle effect on hard water is to precipitate greatly enlarged particles within the water stream.

ASR begins by creating calcium carbonate and corrosion particles that coagulate with the organics creating larger particles. These larger particles can be extracted from the water flow by a filtration system.

ASR can also help enhance the existing method of chemical dosing, as the water in the system is kept cleaner, therefore, reducing the quantity of chemicals and extend regenerative systems.

LASER PARTICLE ANALYSIS

The ASR was tested by the GALAI CIS 100 Computerised Inspection System back on the 18th August 1993. The results supplied by GALAI demonstrated the formation of Large Particle formation.

Only the ASR with its patentedActive Anode in combination with

the Dielectric PTFE turbulencechambers shows these

positive results.

ASR helps prevent Bacteria, Algae & Slime

36%

34%

32%

30%

28%

26%

24%

22%

20%

18%

16%

14%

12%

10%

8%

6%

4%

2%

0%

0 1 2 5 10 20 50 100

150 PARTICLE SIZE PER GROUP (MICRONS)

PA

RT

ICLE

GR

OU

PS

(P

ER

CE

NTA

GE

)

BEFORETREATMENT

AFTERTREATMENT

before treatment

after treatment

ASR questions and answers

WILL ASR AFFECT WATER PRESSURE AND FLOW RATES?The internal configuration of ASR does not noticeably impede the flow or pressure loss with flow rates up

to 2 metres per second.

IS THE WATER TREATMENT DEPENDENT ON FLOW RATES?Unlike many other physical water conditioners, ASR will perform well across a wide range of flow

conditions.

DOES TURBULENT FLOW AFFECT THE PERFORMANCE OF ASR?No. The design of ASR creates turbulence within its

structure in order to improve the treatment effects.

HOW QUICKLY WILL ASR CLEAN A SYSTEM?The time taken will depend on several factors:

• the internal condition of pipework and appliances

• the thickness of scale deposits

• the distance of affected areas from the ASR.

The actual volume of water passing through ASR will determine the length of time taken to clean scale from the system. However, once installed, ASR will commence its job immediately provided that a water flow is still possible.

WILL ASR SOFTEN THE WATER?No - not in the strict sense of the word ‘soften’. However, because some of the dissolved hardness is precipitated from the water, soap and detergent economies are made possible. A ‘soft’ feel to water is often noticeable.

IS THE TASTE OF WATER AFFECTED?ASR can improve the taste of water by ‘masking’ unpleasant flavours such as chlorine as these are absorbed in the precipitated particles.

WILL IT SAVE ENERGY?Yes. Because ASR will remove existing scale build up

on heating surfaces, such as hot water heaters

and tanks, less fuel is required to heat the water. Athickness of scale of only 3 mm can add 25% to energycosts.

WHY IS ASR BETTER THAN ALTERNATIVE PHYSICAL WATER CONDITIONERS?

• much more versatile

• less dependent on flow conditions

• protects against both corrosion and scale

• is a ‘fit and forget’ product

• has no maintenance or running costs

WHERE SHOULD ASR BE SITUATEDIN RELATION TO EQUIPMENT?Ideally the ASR should be located at least one metre from the equipment to be protected by the device. This allows the growth of precipitated particles of scale to take place before the water reaches heat-producing and

scale-forming areas.

HOW LONG DOES THE EFFECT LAST?ASR has been developed with the size of precipitated

particles being a prime consideration. Large particles have a much smaller surface area than the equivalent mass made up of relatively smaller particles. This means they are much slower to re-dissolve in the water and subsequently the treated water has longer lasting effects. Water treated using ASR is likely to continue to do its job of removing old scale deposits from pipe-work for much longer than alternative products, which produce much

smaller particles.

WHY IS IT ESSENTIAL TO EARTH THE ASR?ASR causes the precipitation of carbonates arising from the breakdown of dissolved bicarbonates. The change in

the chemical structure results in a change in electrical charge. If this charge is not allowed to neutralise then the desired changes may be restricted or limited in duration. In the case of the ASR this is achieved by means of grounding the charge to a suitable earth connection.

• Physical hardness can reduced in closed loop applications

The range of applications to which Rotek Anti-Scale Reactor can be used is extensive. Experience over

25 years with the Rotek ASR technology shows that the fundamental requirements vary depending on water

systems, system layout and equipment to be protected.

The requirements will also vary depending on whether

the product is for new construction or refurbishment of an

existing system. Rotek has established a family

of products to cover the range of installations from individual

appliance protection and building usage through to large heavy industrial process applications.

MARKETS

Food and Beverage Processors Hotels

Office Buildings Health Care Facilities

Educational Institutions

Pharmaceutical Manufacturers

Public and Government Facilities

Industrial processes

CUSTOMER BENEFITS

Reduced operation costs Increased equipment life span

Reduction in maintenance Reduction of downtime

Eliminated salt removal cost

Improvement of Health & Safety

Elimination of chemical handlingand storage

ASR-12 Water Conditioner – Cut Sheet

The self-cleaning anode system ROTEK Anti-Scale Reactor ensures protection against

corrosion and calcium deposits in water and piping systems.

The device is WRAS, ACS and TÜV approved and any PTFE used are certified KTW.

All metals are Lead Free for drinking water in accordance with AB1953 (USA) and DIN 50930

(Europe). The device BSP connectors meet the specification DIN 1988 (TRWI).

The ASR conditioner’s dry contact anode requires no external power supply. Designed for

vertical installations or with a filter in horizontal installations, for installation in drinking water

and industrial process water systems.

General:

Make RotekProduct Model ASR-12Connection 1/2” BSP Internal DN15 : ISO 7/1

Total length 120 mm

Outer diameter 25 mm

Weight 0.35 kg

Materials:

Body Lead Free Brass according to DIN EN 12164, CW724R, CW510L or Bronze in accordance with BS EN 1982:2008 CC481K / BS1400 PB1 Surface Treatment: Nickel Plated

Internal Components Anode: Zinc Z2 to BS EN 1179:2003 & Zinc in accordance with ASTM B418 Type2 or Type 1/ MIL-A-18001K Turbulence Body: Polytetrafluoroethylene in accordance with BS EN ISO 13000-1:2005 Retaining Clip SST316L

Design and Working Conditions:

Max. Pressure 10 bar

Nominal Flow Rate 0.57 m3/h @ ∆P 0.05 bar

Design Flow Rate 1.3 m3/h (0.36 l/s)

Max. Flow Rate 2.0 m3/h (0.56 l/s)

Max. Operating Temperature 60OC in drinking water applications

Recognized and certified by

ASR-19 Water Conditioner – Cut Sheet

The self-cleaning anode system ROTEK Anti-Scale Reactor ensures protection against

corrosion and calcium deposits in water and piping systems.

The device is WRAS, ACS and TÜV approved and any PTFE used are certified KTW.

All metals are Lead Free for drinking water in accordance with AB1953 (USA) and DIN 50930

(Europe). The device BSP connectors meet the specification DIN 1988 (TRWI).

The ASR conditioner’s dry contact anode requires no external power supply. Designed for

vertical installations or with a filter in horizontal installations, for installation in drinking water

and industrial process water systems.

General:

Make RotekProduct Model ASR-19Connection 3/4” BSP Internal DN20 : ISO 7/1

Total length 157 mm

Outer diameter 32 mm

Weight 0.7 kg

Materials:

Body Lead Free Brass according to DIN EN 12164, CW724R, CW510L or Bronze in accordance with BS EN 1982:2008 CC481K / BS1400 PB1 Surface Treatment: Nickel Plated

Internal Components Anode: Zinc Z2 to BS EN 1179:2003 & Zinc in accordance with ASTM B418 Type2 or Type 1/ MIL-A-18001K Turbulence Body: Polytetrafluoroethylene in accordance with BS EN ISO 13000-1:2005 Retaining Clip SST316L

Design and Working Conditions:

Max. Pressure 10 bar

Nominal Flow Rate 1.83 m3/h @ ∆P 0.06 bar

Design Flow Rate 4.5 m3/h (1.25 l/s)

Max. Flow Rate 6.5 m3/h (1.80 l/s)

Max. Operating Temperature 60OC in drinking water applications

Recognized and certified by

P. 1

Installation Specifications

The Water

An analysis of the water should preferably be submitted when proposing to use the ROTEK Anti-Scale Reactor (ASR) with industrial or well water. The use of the ASR with water witha temperature over 140°F (60°C) is not always desirable. The manufacturer should be

consulted if it is intended to install the ASR in a system of piping with water temperaturesover 140°F (60°C) or where the values of the ‘drinking water directive’ (TVO-conductivity

and/or pH values) are exceeded. There should be no significant variation in the water quality

or operating conditions during usage.

The ROTEK Anti-Scale Reactor

The ROTEK Anti-Scale Reactor (ASR) is physical device for inline installations only andmust be kept wet once usage commences.

The pressure drop with proper use of the ASR is minimal. It should be noted that the flowrate of the chosen ASR should be at or above the nominal flow rate of the connectedwater system but below maximum flow rate as noted on the specification of the specific

model. Due to the symmetrical construction of the ASR the direction of the water flow canbe from either end of the device. The model and size of ASR to be selected should bedetermined by the maximum flow rate demand in the system of installation. In residential, the

size of the water meter will typically determine the size of the ASR.

The Installation (see diagrams)

It is recommended that a company specialising in this field should install the ROTEK Anti-Scale Reactor (ASR) . Depending on the length and model of the device selected, a sectionof the piping should be removed, two compatible coupling connections installed properly and

then the ASR installed.The ASR should be installed preferably vertically and upstream of a filter, if present, or thepressure booster station.

When installing the ASR in a stainless, black or galvanized steel or copper piping systemthe device must be electrically bridged using suitable bonding wire. When installing the

ASR in a plastic piping system pieces of piping of a metallic nature at least the length ofthe ASR must be inserted into the pipeline before and after the ASR. In these casesa grounding wire must be connected to a physical grounding point.

The ASR should be installed as close as possible to the individual pieces ofequipment to ensure their protection (e.g. heat exchangers, pumps etc.).

P. 2

Caution!

During installation in a copper piping system the ROTEK Anti-Scale Reactor (ASR) mustnot be exposed to the heat from the soldering. The ASR must not be levered or turnedagainst the screw joint ends or flange couplings. Pipe wrench or spanners should only be

used on the couplings and never on the ASR itself. The ASR must be installed with zeropotential (good grounding).

Central Warm Water Processing with a Circular Flow System

If the heating equipment, which is being protected by ROTEK Anti-Scale Reactor (ASR),also contains a warm water circulation loop, an additional ASR, should be incorporated inthe pipe work of the loop to provide protection against scale and corrosion. This ensures

efficient after-treatment and enables the whole system to be protected. In case the system

has multiple loops, each and every one should be equipped with one ASR.

Caution! Additional Information about the Flanges ROTEK Anti-Scale Reactor (all E models above DN50 or U models above 2”)

To ensure the correct installation of the flanged device, only proper standard flange seals

(DN for ASR E models, ASME/ANSI gaskets for ASR U models) should be used. If thegaskets are damaged or lost during installation, new proper standard gaskets should be

obtained. Further, the bolts must be secured using washers with spring rings (supplied).

If these requirements are disregarded the guarantee of the device in connection with the

warranties will be null and void. The flanged devices have indicator strips between the

device and the flange. The warranty becomes void if one or both of the strips are

damaged either through rotation of the flange thus causing leaks or due to levering or

some similar activity. Under no circumstances should the ASR be pulled apart usingattachment bolts to make the device fit!

Filter

If a fine filter is present then the ROTEK Anti-Scale Reactor should always be installeddownstream of the fine filter – even in a circulation flow system. It is recommended that a

fine filter should be installed upstream of the ASR if there are problems with debris due tobad corrosion etc. (for RO application, ASR can be installed at the upsteam of the pre-filter)

P. 3

Electrical Earth (Ground) Bonding

Schematic A

Where pipe-work is metal, properly grounded (earthed) and with no feedback from any stray currents from electrical equipment.

Schematic B

Where pipe-work is metal, properly grounded (earthed) but with the potential/actual feedback of stray currents from electrical equipment.

Schematic C

Where pipe-work is not adequately grounded (earthed).

Schematic D

Where ASR is installed into plastic pipe-work itis important that metal pipe-work is installed

both before and after the ASR. The ideal lengthof pipe-work before and after should be the pipe diameter x30 wherever possible.

Electrical Earth Bonding

Electrical earth bonding (grounding) is essential to enhance the performance of ROTEK Anti-Scale Reactor in addition to providing a safe continuity of earth bonding for otherpurposes. When plastic pipes are used be sure to bond the actual ASR to a grounding point(earth) and be aware that the lacquer/nickel plated finish may be required to be pierced to

achieve an effective earth (ground).