Kamco CF30 SM
Contents
1. 23 Return to re circulation mode and move to page B 10 Issue Sept 2008 Section B Using the CF30 for Power Flushing Page B 8 Kamco CHEMICAL FLUSHING PROCEDURE USING HYPER FLUSH CLEARFLOW CF30 CLASSIC OPERATING SERVICING GUIDELINES 1 Switch on the CF30 12 When you have flushed the last radiator and it has an even temperature across the surface 2 Whilst re circulating water switch the CF30 into dumping mode as through the CF30 and the previously heating system slowly add 1 litre of HYPER FLUSH to the 13 With only this radiator open and the CF30 set to CF30 tank sufficient for 10 12 dump run until the water leaving the dump hose radiator system unless it was is completely clear Now operate the flow added on a prior visit and reverser and change the valves to dump in the ensure thorough distribution opposite direction until clear When dump water around the system is clear close radiator valve Switch on the boiler if fitted and in safe working 14 Go back to the previous radiator that you had order Allow the system water to reach 50 C and flushed ensure both valves are open and repeat then switch boiler off the dumping procedure on this one radiator NOTE Even boiler thermostat setting no 1 alternating the direction of flow in each direction could exceed 50 C as you dump Close radiator valve Circulate throughout the complete system for half 15 Work your way back around the house in2. Use FX2 as usual on the day of the power flush adding directly into the CF30 tank Page B 6 Section B Using the CF30 for Power Flushing Issue Sept 2008 GTCO CHEMICAL FLUSHING PROCEDURE USING POWER FLUSH 2 CLEARFLOW CF30 CLASSIC OPERATING SERVICING GUIDELINES 1 Switch on the CF30 12 When you have flushed the last radiator and obtained an even temperature across the 2 Whilst re circulating water surface switch the CF30 into dumping mode as through the CF30 and the previously heating system slowly add 2 Itr of Powerflush FX2 to 13 With only this radiator open and the CF30 set to the CF30 tank sufficient dump run until the water leaving the dump hose for 10 12 radiator system is completely clear Now operate the flow and ensure thorough reverser and change the valves to dump in the distribution around the opposite direction until clear When dump water system is clear close radiator valve Switch on the boiler if fitted and in safe working 14 Go back to the previous radiator that you had order Allow the system water to reach 50 C and flushed ensure both valves are open and repeat then switch boiler off the dumping procedure on this one radiator NOTE Even boiler thermostat setting no 1 alternating the direction of flow in each direction could exceed 50 C as you dump Close radiator valve Circulate throughout the complete system for 15 15 Work your way back around the house in the min
3. Dump T Dump valve valve closed closed Position of the Clearflow valves during normal CIRCULATION through the heating system Isolating Isolating valve valve open Flow reverser lever can be in either direction reverse flow regularly Position of the Clearflow valves when DUMPING dirty water to waste Isolating valve Isolating open p closed When flow reverser is in direction A waste water will be expelled through dump valve A with dump valve B closed Issue Sept 2008 Section B Using the CF30 for Power Flushing Page B 5 CLEARFLOW CF30 CLASSIC OPERATING SERVICING GUIDELINES amco CHEMICAL FLUSHING PROCEDURE WHICH CHEMICAL TO USE Which chemical to use POWERFLUSH FX2 or HYPER FLUSH Both of these chemicals will remove sludge and scale from a central heating system HYPER FLUSH Use Hyper Flush when The system contains aluminium radiators or heat exchangers You consider the system to have suffered severe internal corrosion and metal wastage The system has elderly galvanised steel or stainless steel pipework installed during the 1960s copper shortage crisis How much to use 1 litre per ten radiators or two litres if you consider the system to be heavily sludged Where and when to add HYPER FLUSH Into the system 3 14 days prior to power flushing via the F amp E tank or a SYSTEMSURE injector unit Directly into the CF30 tank whilst power flushing T
4. and dissolve more stubborn L_y o Open Closed accumulations of debris 1 Leave the pump tank cap off or on by no more By doing this system water is diverted to waste than one turn if water splashes whilst flushing down the dump hose instead of returning back descaling to allow gas to escape into the tank The liquid level in the Clearflow tank will immediately begin to fall 2 Check that both dump valves are closed Open the isolating valves between flushing pump and heating system and switch on pump immediately Ensure that liquid level in tank remains at least 10 cm above the minimum mark adding more water if necessary Closed B _ Closed Position of pump valves during normal operation with full circulation through heating system both isolating valves open and dump valves closed 5c The mains water inlet supply orange tap should now be turned on and adjusted so that the volume of incoming water compensates for that being forced out of the system to waste Continue dumping until the waste water runs relatively clear Ensure that liquid level in tank remains at least 15 cm above the minimum mark at all times 3 Allow Clearflow pump to run for ten minutes reversing the direction of flow regularly If there is sludge and debris in the system the water returning into the tank will be heavily discoloured as the high flow rate picks up looser debris 4 Check all hoses and connections f
5. 2 Water inlet valve W 1 Sa Issue Sept 8 CLEARFLOW CF30 CLASSIC OPERATING SERVICING GUIDELINES A pair of 2 metre long adapter hoses enabling the Clearflow to be connected across the 1 1 2 unions is supplied as standard When used these are screwed directly onto the female brass hose adaptors of the flow and return hoses giving a total hose length of 5 metres Connection via the optional CP2 pump head adaptor see page G 2 Remove the allen bolts that attach the circulation pump head to the pump body Attach the adaptor to the pump body and the flow and return hoses to the short lead hoses Across the tails of a radiator having drained and disconnected the radiator using appropriate 1 2 or 3 4 BSP adaptors to connect to the valves The radiator valves should be closed to isolate the flushing pump from the system until power flushing is commenced This is likely to be the least effective method due to the restrictive effect that valves particularly thermostatic may have on the flow rate The above method is generally used on a combination boiler system when a CP2 adaptor is not available Across the flow and return connections at the boiler isolating the boiler itself This is the preferred method when flushing a heating system prior to installing a new boiler as corrosion debris may be purged from the heating system before t
6. Zone Yr Sl K valve out Cold feed water inlet Hot Water Storage Radiator Cylinder Radiator Clearflow connections bw VSD Radiator Radiator Radiator gt gt MAg Bypass e should py be closed To waste Generally the unit should be located in a room with a suitable drain point and near to a convenient mains water supply such as a bathroom or kitchen The cold water supply for a washing machine or dish washing machine is a convenient source when a mixer tap makes connection of a hose difficult The normal precautions during work on any heating system should be taken and it is prudent to place the pump on a waterproof groundsheet or drip tray Dump hose Connect onto the valve bodies having left these attached to flow and 1 2 BSP Connection for water inlet hose Flow return hoses with 3 4 brass connections both ends Section B Using the CF30 for Power Flushing Remove one radiator only and connect across the pipe tails return piping Leave the system circulator pump in place although electrically isolated The connection point for the Clearflow pump may vary depending on the system to be cleaned and the availability of suitable connection points However the optimum location is via the central heating circulation pump using either the special hoses supplied to connect across the pump unions or using the optional CP2 adaptor connected to the pump body see page F
7. the to one hour reversing the flow direction regularly opposite direction to previously until you have and monitoring the system for leaks carried out the dumping process on every radiator individually Close off all radiators one valve only and allow the full flow to go through the coil in the cylinder 16 Now with the CF30 still set to dump direct the if present in the system flow through the cylinder coil until it runs clear Dump in the other direction until clear Reverse the flow regularly 17 If you have a TDS meter Total Dissolved Solids Divert the full flow to the radiator circuit in it is useful to test the water at this stage preparation to putting the full flow of the CF30 The reading should be compared with a mains through each radiator in turn water sample reading and the dumping process continued until both readings are within 5 of Fully open both valves of the nearest radiator on each other the ground floor to the CF30 18 Return the CF30 into normal re circulation mode Flush this radiator reversing the flow regularly re open all radiator valves and the cylinder coil until all cold spots have disappeared and the and move to page B 10 temperature across the radiator is consistent Close the radiator valves 19 NOTE When using HYPER FLUSH there is no requirement to neutralise after the flushing process Page B 9 Section B Using the CF30 for Power Flushing Note If your in
8. A Kamco CLEARFLOW CF30 CLASSIC OPERATING SERVICING GUIDELINES 30 d CLEARFLOW CF30 CLASSIC OPERATING SERVICING GUIDELINES The Kamco CLEARFLOW CF30 CLASSIC pump is a purpose built unit for Power Flushing central heating systems designed to cure circulation and boiler noise problems caused by the accumulation of sludge corrosion deposits and scale This manual contains detailed guidelines for the safe use of the pump How to connect the pump into the heating system step by step guide to the flushing process and which chemicals are best suited for each application Please take time to carefully read through these guidelines before using your Kamco pump Kamco Ltd Unit 9 Curo Park Frogmore Park Street St Albans Hertfordshire AL2 2DD Tel 01727 875020 Fax 01727 5 Additional information may be obtained from our website www kamco co uk ki TEF OES n ee EO A e eal Eir eee oo 1 i EL 1 Issue September 2008 CLEARFLOW CF30 CLASSIC amco d 7 OPERATING SERVICING GUIDELINES SECTION A INTRODUCTION TECHNICAL DATA Pump Type Positive drive centrifugal Motor 0 45 HP 220v or 110v Degree of protection IP54 Motor rating Continuous Temperature range 0 C to 70 C Dimensions Height 63cm Diameter 41cm Weight 14kg The CLEARFLOW CF30 220v may be used on a domestic 13 ampere supply A 5amp fuse should
9. F30 for Power Flushing INTRODUCTION The CLEARFLOW CF30 pump is designed to power flush heating systems with minimal dismantling by circulating water and flushing chemicals at high velocity and then purging the dirty water from the system with a high flow of fresh clean water Radiators may be individually flushed without removing or disconnecting them from the system Your Clearflow pump may be used with any commercially available flushing and descaling chemical including strong acids or alkalis SYSTEM INSPECTION AND PREPARATION 1 Turn on heating system in order to identify problem flow areas cold radiators or those with cold spots etc Switch off system 2 Note how many turns are required to shut off radiator and lock shield valves so that settings may be re instated after flushing to avoid system balancing Use a copy of the chart provided to record the number of turns Open all both sides of radiator valves fully 3 Set any thermostatic radiator valves to the fully open position Remove the heads and check that the plunger pin moves freely Check that diverter or zone valves are in the fully open position setting manually if necessary 4 If an anti gravity check valve is present this must be by passed or bridged to allow the flow reversing action to be used It may be possible to dissemble the anti gravity valve and remove internal components 5 Tie up the ball cock or turn off the mains water supply
10. be fitted in the plug top A residual current circuit breaker adaptor should be used SAFETY PRECAUTIONS Precautions should be taken to ensure a safe working environment Take care when lifting large or heavy items Regularly check power leads for wear or damage use with a residual circuit breaker When handling chemicals wear suitable protective clothing gloves and goggles Use in a well ventilated area PAT test Portable Appliance Test the electrics annually CONTENTS OF THE CLEARFLOW CF30 CLASSIC KIT Each kit comprises the following CLEARFLOW CF30 Classic power flushing pump Set of 2 x 3mtr flow and return hoses 1 8mtr dump hose 1 3mtr overflow hose 1 Smtr water inlet hose 2 x 2mir circulation pump adaptor hoses 10 part BSP adaptor set Waterproof transit container Comprehensive operating guidelines Starter pack of flushing chemicals 50 promotional leaflets for advertising Issue September 2008 Section A Introduction Page A 1 CLEARFLOW CF30 CLASSIC OPERATING SERVICING GUIDELINES Kamc 8 SECTION B USING THE 6 30 FOR POWER FLUSHING Pumps with 220 volt motors are single phase for use on a standard domestic supply A five amp fuse should be fitted in the plug top We recommend the use of a residual current circuit breaker plug or adapter for extra protection Looping the feed and expansion pipes together will enable these pipes to be flushed during the cleansing process wh
11. by another means 6 Drain enough water from the system to empty the F amp E tank This can be drained into the CF30 if it has been connected connection details are in the next section 7 With vented systems it is necessary to cap off or loop together the expansion and cold feed pipes in order to avoid the powerful CF30 filling and overflowing the expansion tank The F amp E pipes may be capped with push fit end caps such as Speedfit Prestek or Hep2O or a temporary compression fitting gate valve Issue Sept 2008 CLEARFLOW CF30 CLASSIC OPERATING SERVICING GUIDELINES amco LOCATION AND CONNECTION OF THE CLEARFLOW PUMP To avoid overflow of the expansion tank in vented systems the cold feed and expansion pipes need to be capped off If the cold feed and expansion pipes are not connected into the system in close proximity looping them together will enable flushing chemical to circulate up the cold feed pipe which often has deposit problems where it enters the heating system The loop should incorporate an isolating valve Hot water Alternative connection locations 1 2 and 3 for a CLEARFLOW power flushing pump Water in Feed and expansion cistern Easiest method Connect across the circulator pump fittings using the supplied adapters after removing the pump Connect across the flow and return pipes to the boiler use this location when installing a new boiler to an old oi
12. culating throughout the system Circulate throughout the system for ten to fifteen minutes Continued on next page 806 7 19 Section B Using the CF30 for Power Flushing Note If your initial system check identified cold or partially blocked radiators commence the individual radiator flushing procedure with the worst radiator first progressing to less problematic radiators This ensures that the strongest concentration of chemical is directed at the worst areas of the system 10 Open the valves on the next radiator and repeat the procedure 11 Work through the rest of the radiators in turn so that you have flushed every radiator individually including upstairs radiators Issue Sept 2008 CLEARFLOW CF30 CLASSIC aimco gt OPERATING SERVICING GUIDELINES 20 Switch the CF30 into dumping mode 21 After dumping for ten minutes with coil and all radiators wide open test the dump water with pH paper Continue dumping until a pH reading of 7 is reached or the same reading as the mains water supply in the property is achieved both samples show the same colour Note As an alternative an electronic pH meter may be used see page F 11 22 If you have a TDS meter Total Dissolved Solids it is useful to test the water at this stage The reading should be compared with a mains water sample reading and the dumping process continued until both readings are within 5 of each other
13. emperature required HYPER FLUSH works best at higher temperatures and when used to pre treat a system it should be operated as hot as possible However the very high flow rate of the CF30 means that during power flushing it is not necessary to work at temperatures above 50 C POWERFLUSH FX2 Use Powerflush FX2 when You consider the system to be heavily sludged although basically sound and in reasonable condition There are no aluminium heat exchangers or radiators present in the system The system does not have elderly galvanised steel or stainless steel pipework installed during the 1960s copper shortage crisis You consider that there may be limescale deposits present in the boiler or system How much to use 2 1 2 litres per ten radiators or a little more if you consider the system to be heavily sludged Where and when to add FX2 Into the tank of the CF30 whilst powerflushing but not beforehand Temperature required FX2 may be used cold necessary when changing a boiler but works faster with a higher temperature The very high flow rate of the CF30 means that during power flushing it is not necessary to work at temperatures above 50 C NEVER LEAVE FX2 IN A SYSTEM Use both HYPER FLUSH and FX2 if you consider the system to be VERY HEAVILY SLUDGED Add HYPER FLUSH on a prior visit up to 14 days before the power flush and ask the householder to leave the system running as hot as possible
14. he new boiler is attached This is important with all modern boilers particularly so if the new boiler incorporates a plate type heat exchanger with complex and narrow water passages Page B 3 2b 2C 2d Section B Using the CF30 for Power Flushing Kamco 1 Hose connections to the CF30 1a Ensure that the isolating valves either side of the Clearflow flow reverser are in the closed position 1b The Clearflow CF30 has two 3 metre flow and return hoses fitted with 34 female brass hose connectors on either end of each hose One end of both flow and return hoses should be screwed onto the corresponding brass nipples on either side of the Clearflow pump adjacent to the blue metal valve support brackets The other ends of these hoses will be connected into the heating system 1c Connect the plastic overflow hose connector to the 3 4 BSP male overflow fitting on the pump tank and lead to a suitable drain pipe gully or bucket 1d The dump hose has two brass hose connectors and tubes connected with a Y piece to the main length of dump hose Connect both dump hose connectors to the 4 male outlets of the dump valves and lead the hose toa toilet pan or drain pipe gully leading to a foul sewer 1e Connect mains water supply hose 1 2 BSP female hose connector securely to the 1 2 BSP male fitting attached to the orange waiter inlet valve on the top flange of the pump Fill C
15. ich can be beneficial when the cold feed pipe contains corrosion deposits NOTE 1 This will only be effective when the F amp E pipes are not close coupled or connected via an air separator and may not remove deposits which have hardened over a long period of time NOTE 2 The looping connection may be made with any sturdy flexible tubing such as CF30 hose or Hep2O but should incorporate a valve in the loop to close the circuit when flushing individual radiators Capping or looping the F amp E pipes are only temporary measures which must be removed after the flushing process ENGINEER S TIP Don t drain water from the system to lower the water level in the F amp E tank until after the Clearflow pump has been connected into the system Tie up the f amp e tank ballcock or otherwise turn off the cold water feed and return to the Clearflow pump Open both the isolating valves without switching on the electric motor The head of water in the house means that heating system water will run down the flow and return hoses and into the Clearflow tank Let the water run until the tank is half full and close both isolating valves You should now have emptied the f amp e tank sufficiently to carry out the necessary valving or capping off of the cold feed NOTE If there is a large amount of sludge or slime present in the f amp e tank it must be cleaned manually and not drained into the system 806 1 Section B Using the C
16. itial system check identified cold or partially blocked radiators commence the individual radiator flushing procedure with the worst radiator first progressing to less problematic radiators This ensures that the strongest concentration of chemical is directed at the worst areas of the system 10 Open the valves on the next radiator and repeat the procedure 11 Work through the rest of the radiators in turn so that you have flushed every radiator individually including upstairs radiators Issue Sept 2008 0 CLEARFLOW 030 amco d 7 OPERATING SERVICING GUIDELINES INHIBITION AND CORROSION PROTECTION The inhibitor may be added to the system by using the Clearflow pump as follows 2 Briefly open a dump valve to lower the water level in the Clearflow tank to 6 cm above the minimum level close the dump valve Add the SYSTEMSAFE DM inhibitor into the tank Allow circulation through the system for ten minutes isolate the flushing pump from the heating system and switch off IMPORTANT 1 The system is now full of fresh clean water and in line with Building Regulations Part L 2006 a 3 If the system is vented the residual water in the good quality corrosion inhibitor Clearflow tank which will contain a small quantity SYSTEMSAFE DM must be added to the system of inhibitor may be poured ne water to prevent further corrosion and scaling added to the F amp E tank after this has been cleaned T
17. learflow tank with water to 15cm above the minimum liquid level and then close the water inlet valve 1f Plug in the CF30 to a suitable 13 amp supply fitted with an RCD adapter 2 Hose connection to the system Connect the flow and return hoses of the Clearflow pump to the system at the selected point This may be either 2a Across the 1 1 2 BSP unions left once the circulating pump has been removed The circulating pump isolating valves should be closed to isolate the flushing pump from the system until power flushing is commenced Issue Sept 2008 6 CLEARFLOW 6 30 alnco d d OPERATING SERVICING GUIDELINES INITIAL FLUSHING PROCEDURE WATER ONLY STAGE BEFORE ADDITION OF CHEMICALS Note In the following procedure the Clearflow 5b Close the isolation valve on the opposite side CF30 is first used to loosen and mobilise loose from the direction in which the flow reverser lever silt and debris before forcibly expelling it together is pointing and open the dump valve on this side with the existing heavily contaminated system water This rids the system of as much debris and Closed sludge at an early stage before establishing full Position of the chemically treated circulation through the CLEARFLOW Clearflow pump pump valves when dumping By removing loose corrosion products from the ORES T system before addition of any chemical the full A a effect of the chemical is available to disturb loosen
18. ly with Bench kd tation E ears ad Note In a pressurised system the inhibitor may Domestic Water Treatment Association product be injected into the system using an IK6 injector performance standard and can be identified by which will avoid wasting any inhibitor left in the this logo on the pack CF30 tank see page F 5 BUILDCERT Approved to the DWTA Performance Standard UPON COMPLETION 1 Restore system to normal restoring radiator The CLEARFLOW CF30 is also a very powerful balance valves to original settings removing any descaling pump suitable for use when descaling temporary isolating valves or caps on the combination boiler domestic water heat expansion and cold feed pipes and restoring non exchangers any conventional domestic boiler return valves to normal operation if necessary water heaters direct fired water heaters thermal store type water heaters showers and 2 Before re connecting the feed amp expansion tank it calorifiers should be thoroughly cleaned removing all traces of dirty water and sludge and then disinfected with Kamchlor chlorine release tablets Issue Sept 2008 Section B Using the CF30 for Power Flushing Page B 10
19. or leaks Note If the mains water cannot keep up with the dump speed i e the unit begins to empty simply stop dumping until the tank fills up NEVER turn the dump valve to half open position because this will reduce the flow rate in the system 5 The CLEARFLOW CF30 has a dump valve on both sides of the unit enabling water to be dumped with the flow in either direction Change the Clearflow into dumping mode as follows remembering that the flow reverser is constructed so that the direction in which the lever points also indicates the direction of flow 6 Once the water remains reasonably clear restore circulation by ensuring Both isolating valves are open Both dump valves are closed 5a Operate the flow reverser lever so that the water is flowing through the heating system in the same direction as it is during normal heating operation Continued on next page Issue Sept 2008 Section B Using the CF30 for Power Flushing Page B 4 Kalmco d y CLEARFLOW CF30 CLASSIC OPERATING SERVICING GUIDELINES 7 Check that the liquid level in the tank remains 8 The flushing chemical may now be added See 15cm above the minimum mark Add more water page B 6 if necessary Vent all radiators to ensure that there are no air pockets Use a cloth to absorb any liquid expelled as the system water may be Leave the pump tank cap off or on by no more discoloured and likely to stain than one turn whilst flushing descaling
20. utes reversing the flow direction regularly opposite direction to previously until you have and monitoring the system for leaks carried out the dumping process on every radiator individually Close off all radiators one valve only per radiator is enough and allow the full flow to go through 16 Now with the CF30 still set to dump direct the the coil in the cylinder if present in the system flow through the cylinder coil until it runs clear Dump in the other direction until clear Reverse the flow regularly Note You have used an acidic cleaner and Divert the full flow to the radiator circuit in therefore a neutralising chemical should be preparation to putting the full flow of the CF30 circulated throughout the system to ensure that through each radiator in turn no traces of FX2 remain in the system Whilst FX2 contains specific inhibitors so that its Fully open both valves of the nearest radiator on presence during a power flush presents no the ground floor to the CF30 problems it is bad practice to leave system water acidic over a long period of time Flush this radiator reversing the flow regularly until all cold spots have disappeared and the 17 Return the CF30 into normal re circulation mode temperature across the radiator is consistent re open all radiator valves and the cylinder coil Close the radiator valves 18 Slowly add 100 gm of NEUTRALISING CRYSTALS to the water in the pump tank whilst cir
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