SPECSHEET

CALORIFIERS
ALL CALORIFIERS CARRY A NAME PLATE SPECIFYING THE FOLLOWING:
Date of Manufacture.
Maximum working pressure, test pressure.
Calorier Capacity.
ThermoWise CALORIFIERS SHEET | 01

THEROWISE
THEROWISE CALORIFIERS
CALORIFIERS 01 01

OVERVIEW
OVERVIEW
PRODUCT
PRODUCT SPECIFICATION
SPECIFICATION
Distribute, delivery
Distribute, and installation
delivery of caloriers
and installation for theforsuppl
of caloriers the ysuppl
of commercial hot water,
y of commercial for water
hot water, for systems with a with
water systems pressure
a pressure
of 600kPa and standard
of 600kPa tank size
and standard tankup t o up
size 10 t000
o 10litres.
000 Certication of vessels
litres. Certication by an by
of vessels independent testing testing
an independent authority is available
authority is available
on r equest.
on r equest.

HEATING METHOD
HEATING METHOD
The heating method
The heating shall be
method either
shall through
be either the integral
through heatingheating
the integral elements or through
elements the external
or through air to water
the external air to Heat
waterPump.
Heat Pump.
The heating medium
The heating could could
medium also be by be
also anybymeans of steam
any means passedpassed
of steam throughthrough
a suitably sized heating
a suitably coil. coil.
sized heating

TREATING METHOD
TREATING METHOD
1. GALVANIZED
1. GALVANIZED
Galvanized metal metal
Galvanized is simply steel in
is simply some
steel form that
in some formhas
thatreceived a thin acoating
has received of zincofoxide.
thin coating The purpose
zinc oxide. of the of
The purpose zincthe zinc
is to is
protect the steel
to protect the from
steel elements that normally
from elements would would
that normally lead tolead
oxidation, corrosion
to oxidation, and theand
corrosion eventual weakening
the eventual of the of the
weakening
steel. steel.

2.1 BLAST CLEANING

2.1 BLAST CLEANING
WhenWhen
viewed without
viewed magnication,
without the surface
magnication, shall be
the surface freebefrom
shall free visible oil, grease
from visible and dirtand
oil, grease anddirt
from
andmill
fromscale,
mill rust,
scale, rust,
paint paint
coatings and foreign
coatings matter.matter.
and foreign Any remaining traces traces
Any remaining of contamination shall show
of contamination shall only
showasonly
slight
as stains
slight in the form
stains in theofform of
spots spots
and stripes.
and stripes.
2.2 ZINC FLAME
2.2 ZINC SPRAY
FLAME SPRAY
WhenWhena tanka istank
flame sprayed
is flame it goesit through
sprayed the process
goes through where where
the process zinc/aluminium wire iswire
zinc/aluminium fedthrough a hand-held
is fedthrough apparatus
a hand-held apparatus
that mixes the wire with oxygen and acetylene. This allows the wire to be broken down and attach itself to the metal it
that mixes the wire with oxygen and acetylene. This allows the wire to be broken down and attach itself to the metal it
is being applied to.
is being applied to.
2.3 PENGUARD PRIMER
2.3 PENGUARD PRIMER
Penguard Primer is a two-pack epoxy primer based on epoxy resin with high molecular weight.
Penguard Primer is a two-pack epoxy primer based on epoxy resin with high molecular weight.
This product is a part of a complete system which is certified not to spread surface flames.
This product is a part of a complete system which is certified not to spread surface flames.

MANUFACTURING METHOD
MANUFACTURING METHOD
ThermoWise is situated in the heart of Durban, South Africa. Today we are proud suppliers to companies such as
ThermoWise is situated in the heart of Durban, South Africa. Today we are proud suppliers to companies such as
Macrotec and Ai-TEC. Thanks to its development strategies all adhere to the new technologies and to the training
Macrotec and Ai-TEC. Thanks to its development strategies all adhere to the new technologies and to the training
of new human resources, ThermoWise is equipped with modern structures and advanced distributing processes.
of new human resources, ThermoWise is equipped with modern structures and advanced distributing processes.

GETTING STARTED
GETTING STARTED AND AND GOING
GOING THETHE DISTANCE.
DISTANCE
GETTING STARTED AND GOING THE DISTANCE.
Due to the nature of the coating we apply, it is advised to ush the vessel once installed. This will cleanse the
Due toof the
vesselDue
nature
to the
debris that
of thethecoating
nature
mayofhave coatingwe
entered we
apply,
apply,
during
it is
is advised
transport
advised totoush
flush
or installation. thethe vessel
vessel
Maintaining theonce
once installed.
installed.
vessel
This
This will
is of utmost
will cleanse
cleanse
importance.the
the vessel of debris
vessel of debristhat
thatmay
may have
have entered
entered during
during transport
transport or installation.
or installation. Maintaining
Maintaining the vesseltheis vessel is of
of utmost utmost
importance.
importance.

ThermoWise
ThermoWise
INTELLIGENT ENERGY SA VING SOLUTIONS
INTELLIGENT ENERGY SA VING SOLUTIONS
ThermoWise CALORIFIERS SHEET | 03
THERMOWISE CALORIFIERS 03

PRODUCT SPECIFICATIONS
STANDARD CAPACITIES AND kW RATINGS
The standard capacities and kW ratings based on heating water over a ve hour period from 10C to 60C are given in the
table below. Capacities may vary according to special customer needs.

Capacity Diameter Weld to Weld Overall Height Dry Weight STD Loading
500 750 1000 1600 180 9kW
1000 920 1400 2000 260 12kW
1500 1070 1500 2200 330 18kW
2000 1070 2100 2750 380 24kW
2500 1280 1800 2500 450 24kW
3000 1280 2100 2700 530 36kW
3500 1280 2400 3100 580 36kW
4000 1450 2200 3000 620 36kW
4500 1500 2300 3100 675 48kW
5000 1600 2200 3000 740 48kW
6000 1800 2300 3200 1000 60kW
7000 1900 2300 3200 1075 72kW
8000 2050 2200 3200 1150 84kW
9000 2100 2300 3500 1250 84kW
10000 2100 2600 3800 1400 96kW

We use 6% Toroshpherical Dished ends constructed from 300WA plate.

Dished end thickness range from 5mm to 10mm dependant on the diameter.
610mm to 1070mm dished ends are 5mm in thickness.
1220mm and bigger dished ends are 6mm in thickness up to 10mm.
The shell is also constructed from 300WA steel and has a minimum thickness of 5mm.
Tanks that are bigger than 5000lt have shells that range from 6mm to 8mm in thickness.
We weld prep our plates as well as our dished ends to create a perfect butt-weld.
A 400NB manhole is in place in every vessel for cleaning and inspection purposes.
The standard vessel has seven 2 inch sockets, for water inlets and out lets as well as extra sockets.
It also has two inch sockets for temperature and pressure gauges.
It has a inch socket for a sacricial anode placement. When electrolysis takes place in the tank, it
will act on the sacricial anode before compromising the internals of the tank. The sacricial anode is
a replaceable item.
The tank also has a 1 inch drain socket on the bottom of the tank.
The tank has 2 lifting lugs. The lugs are 8mm thick welded to a 5mm compad that is welded to the
tank to prevent any external damage to the tank when rigging takes place.
Our tanks come standard with element flanges that is suitable for backup elements.
The tank is welded by means of TIG welding. We perform a standard root run and CO capping weld.
The sockets are welded internally and externally to prevent vessel failure.
Vessels ranging from 500lt to 1500lt can only be galvanized due to internal size restrictions. Vessels above
1500lt can be galvanized or alternatively treated with our in-house treatment method. The treatment
comprises of an extensive sandblast, followed by a coat of Zinc Flamespray. After which it is painted with
2 coats of suitable Apoxy Paint specifically designed for potable water.
The design operating pressure is 600kPa and test pressure is 900kPa. Pressures can be increased with
client request.
We provide full data packs with our tanks which include certication for all material, pressure testing
and welders qualications.
Our vessels are designed in accordance with the specifications of ASME VIII DIV 1: 2010 and
manufactured in accordance SANS 347:2010.

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INTELLIGENT ENERGY SA VING SOLUTIONS
ThermoWise CALORIFIERS SHEET | 05

THERMOWISE CALORIFIERS 05

HORIZONTAL CALORIFIER

LIFTING LUGS

VERTICAL CALORIFIER

MANHOLE LIFTING LUGS

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INTELLIGENT ENERGY SA VING SOLUTIONS
THERMOWISE CALORIFIERS 07
ThermoWise CALORIFIERS SHEET | 06

IDEAL INSTALLATION

The heating method shall be either through the integral heating elements or through the
external air to water Heat Pump.
The heating medium could also be by any means of steam passed through a suitably sized
heating coil.

11

10
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INTELLIGENT
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SOLUTIONS

6
3 8

7
4

PRODUCT DESCRIPTION
1 5000lt Calorier
2 Lever Ball Valve (Full Bore)
3 Pressure Release Valve
4 Mains
5 Air to Water Heat Pump
6 Check Valve (Swing Type)
7 Circulating Pump
8 Up-sized Y Strainer
9 Supply to Building
10 Reticulation Return Line from Building
11 Reticulation Pump
ThermoWise
INTELLIGENT ENERGY SA VING SOLUTIONS
THERMOWISE CALORIFIERS 09
ThermoWise CALORIFIERS SHEET | 07

STEAM BUNDLES
The process by which steam passes through copper tubing to heat up the copper in effect creating
an element effect that functions using steam rather than electricity.

ELECTRIC ELEMENTS
The caloriers heater box or the calorier itself, depending on the heating method, shall be tted
with a 3 phase bank of electrical elements rated as described in sections 2.2 and 2.3. Each
element shall be connected phase to neutral and not phase to phase and be suitable for operating
at 230 volts 10% without any deterioration in anticipated life. The outlet from the heater box shall
be adequately insulated and feed the tank on the upper side or top of the tank to ensure adequate
stratication and that the outlet water temperature is maintained at 60C.

The elements may be either directly immersed in the heater box (Direct Immersion, DI), or be
mounted in pockets (MIP) as selected in the data sheet and shall be wired in groups such that they
can be remotely controlled (and a local manual bypass switch provided) in various groups to avoid
creating power spikes when all clusters were to be switched on.

HEAT PUMPS
At the heart of a modern heat pump is a refrigeration system. Paradoxically, the refrigeration cycle
is an efcient provider of heat as well as cooling and the basics of its operation are quite easily
understood. The heat released during the process of condensing the refrigerant to a liquid is reject-
ed via the heat exchanger directly into air or transferred to heat the water. The air or water
temperature at this point could be 43C to 60C, depending on the design of the system.

PRESSURE RATING
The calorier shall be suitable for operating at a water pressure of 600kPa, but it is a requirement
of the water system designer to ensure that the system pressure in normal or mal-operation does
not exceed 400kPa, or alternatively ensure that a calorier of the appropriate pressure rating is
supplied. Standard pressure testing procedure dictates that you pressure test at 1.5 x operating
pressure. Although we test at 1050kPa.

ThermoWise
INTELLIGENT ENERGY SA VING SOLUTIONS
ThermoWise CALORIFIERS
THERMOWISE CALORIFIERS SHEET1|109

TREATING METHOD
1. GALVANIZED

Galvanized metal is simply steel in some form that has received a thin coating of zinc oxide. The
purpose of the zinc is to protect the steel from elements that normally would lead to oxidation,
corrosion and the eventual weakening of the steel. In this sense, the zinc coating acts as what is
called a sacricial anode. In other words, the zinc will protect the steel from corrosion by acting as a
barrier between the steel and the corrosive agent, at least until the zinc coating has been completely
oxidized.

2.1 BLAST CLEANING

When viewed without magnication, the surface shall be free from visible oil, grease and dirt and
from mill scale, rust, paint coatings and foreign matter. Any remaining traces of contamination shall
show only as slight stains in the form of spots and stripes.

SA 2.5

2.2 ALUMINIUM FLAME SPRAY

When a tank is flame sprayed it goes through the process where zinc/aluminium wire is fed through
a hand-held apparatus that mixes the wire with oxygen and acetylene. This allows the wire to be
broken down and attach itself to the metal it is being applied to. Because the substance cannot
attach to the flat surface of the steel plate, the tank is sandblasted to ISO specication 2.5. Thus
giving the zinc/aluminium a rigid surface to attach itself to. After the flame spay is applied, a liner of
paint is applied, Penguard HB. After a waiting period of 24hrs the second coat of Penguard HB is
applied to nally seal the inside of the tank.

Gun Body

Combination Flame
Fuel In

Drive Rollers
Wire Feedstock

Nozzle
Oxygen In

Target

2.3 PENGUARD PRIMER

Penguard Primer is a two-pack epoxy primer based on epoxy resin with high molecular weight. This
product is a part of a complete system which is certied not to spread surface flames. As a primer
in a coating system for corrosion protection of steel and other substrates. Penguard Primer is also
recommended for internal lining for friction reduction in gas transmitting pipelines.

ThermoWise
INTELLIGENT ENERGY SA VING SOLUTIONS
Manufacturing Process
THERMOWISE CALORIFIERS 13
ThermoWise CALORIFIERS SHEET | 011

MANUFACTURING METHOD
The ThermoWise Group has a proven industrial tradition and is now one of the leading distributors in the
heating and plumbing industry in South Africa.

ThermoWise is situated in the heart of Durban, South Africa. Today we are proud suppliers to companies such
as Macrotec and Ai-TEC. Thanks to its development strategies all adhere to the new technologies and to the
training of new human resources, ThermoWise is equipped with modern structures and advanced distributing
processes.

LAGGING AND CLADDING

QUALITY MANAGEMENT SYSTEM

Isover products are manufactured according to ISO 9001:2008.

FEATURES & BENEFITS

Life long energy savings.

Lightweight & easy to handle.
DIY friendly.
Maintenance free.
Long product life-will not readily age.
Suitable for high humidity applications.
Zero ozone depleting potential(ODP).

FIRE PROPERTIES

Geyser blanket:
Non-combustible - tested to SANS 10177 Part 5.
Class 1 re index rating - tested to SANS 10177 Part 3.
Class A1, s1, do according to EN 13823.
Tested to ASTM E-84.
Flame Spread Index: 20.
Smoke Development Index: 5.

Pipes:
Class 1 re index rating tested to SANS 10177 Part 3.

THERMAL PROPERTIES

Contributes to life long savings by reducing heat loss through the geyser & associated piping due to
the inherent thermal insulation properties.

APPLICATIONS

Geyser & pipe insulation for:

Domestic.
Commercial.
Public sector buildings.

ThermoWise
INTELLIGENT ENERGY SA VING SOLUTIONS
ThermoWise CALORIFIERS
THERMOWISE CALORIFIERS SHEET
1 4 | 12

PHYSICAL PROPERTIES

PRODUCT Rval DIMENSIONS DENSITY k-value Qty / PACK

(m 2 K/W ) (mm) (mm)
Foil Faced 3500 x 1200
Glasswool Blanket 1.28 12kg /m3 0.039 1 roll
x 50
Glasswool Snap on
1.00 15 x 35 88kg /m3 0.033 5 meters
Pipe Insulation

TOOLS NEEDED FOR INSTALLATION

A sharp blade may be needed for cutting.

INSTALLATION INSTRUCTIONS
Wrap the entire geyser (ensure the foil is facing the outside).
Secure the blanket with the binding tape supplied and cut off excess.
Close the ends and tape down.
Install pipe insulation around pipes to and from the geyser (mitre cut pipe sections around
bends).

HANDLING & STORAGE

Store product undercover, and in dry conditions. Store flat. Handle with care, especially on the edges
and corners, which can be damaged if subject to sharp or heavy impact. Do not apply excessive
pressure, for example by standing or sitting on the product, as permanent damage may be caused.

ARCHITECTURAL SPECIFICATION

Install 50 mm thick, non-combustible, lightweight Glasswool Geyser Blanket around geyser or hot
water cylinder. Seal edges with duct tape. Apply 2m of 20mm thick Snap-on Pipe insulation on the
incoming cold water pipes and insulate all outgoing hot water pipes.

Isover reserves the right to alter or amend product specication without notice. The information given
in this publication is correct to the best of our knowledge at the time of publication. Whilst Isover
will endeavour to ensure publications are up to date, it is the users responsibility to check with us
that it is correct prior to use.

The plate used in the insulation process is 0.8mm galvanised sheets. Stainless steel is also available.

GETTING STARTED AND GOING THE DISTANCE

Due to the nature of the coating we apply, it is advised to flush the vessel once installed. This will
cleanse the vessel of debris that may have entered during transport or installation. Maintaining the
vessel is of utmost importance. This will involve the tank being drained every 6 months and rinsed
with cold water and washed down on the inside. This will prevent additives in the water from effect
the lining of the vessel.

ThermoWise
INTELLIGENT ENERGY SA VING SOLUTIONS
Lagging & Cladding
SPECIALISTS IN AIR TO WATER HEAT PUMPS
Contact us: 0860 HEAT H20 / 0860 4328 420
Tel: +27 31 569 4453 Fax: +27 31 569 3523
www.thermowise.co.za