Kamco CF40 Evolution Owner's manual

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023
Kamco ‘CLEARFLOW' pumps are purpose-built units 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 Kamco pumps, information on how to connect
the pump into the heating system, a step-by-step guide to the power flushing process, and information on
which chemicals are best suited for each application.
Please take time to carefully read through these guidelines before using your Kamco pump.
Kamco Ltd
Curo Park, Frogmore, Park Street,
St. Albans, Hertfordshire, AL2 2DD
Tel: [phone]
E-mail: [email protected]
Additional information may be obtained from our website:
www.kamco.co.uk
Twitter: @KamcoPF
Watch the ‘Brief guide to power flushing’ video at:
https://www.youtube.com/watch?v=TJn9LrRfXm8&t=28s

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Contents Page 1
MAIN CONTENTS
Section A –Introduction Page
Technical data ............................................................................................................................................... A.1
Safety precautions......................................................................................................................................... A.1
Contents of each Clearflow flushing kit .......................................................................................................... A.1
Section B –Using the Clearflow pump for power flushing Page
Introduction ...................................................................................................................................................B.1
System inspection and preparation.................................................................................................................B.1
Location and connection of the Clearflow pump .............................................................................................B.2
Initial flushing procedure (water only) ............................................................................................................B.4
Chemical flushing procedure –which chemical to use.....................................................................................B.6
Chemical flushing procedure –using PowerFlush FX2 .....................................................................................B.7
Chemical flushing procedure –using HyperFlush.............................................................................................B.9
Inhibitor and corrosion protection................................................................................................................B.10
Upon completion..........................................................................................................................................B.10
Quick guide to power flushing ......................................................................................................................B.11
Summary of chemicals used when power flushing ........................................................................................B.12
Radiator valve settings..................................................................................................................................B.13
Power flushing survey and check list.............................................................................................................B.14
Power flush monitoring form........................................................................................................................B.16
Section C –Frequently Asked Questions (FAQs) about power flushing Page
Questions and answers...................................................................................................................................C.1
Section D –Using the Clearflow for descaling boilers and heat exchangers Page
Descaling procedure...................................................................................................................................... D.1
Summary of chemicals used when descaling.................................................................................................. D.2
Section E –Service and repair Page
Trouble shooting and performance testing .....................................................................................................E.1
Trouble shooting flow chart............................................................................................................................E.2
CF40 & CF90 exploded view, spares diagram and spares list............................................................................E.3
CF210 Exploded view, spares diagram and spares list......................................................................................E.8
Section F –Optional power flushing accessories Page
Introduction ...................................................................................................................................................F.1
CP2 circulator pump body adapter..................................................................................................................F.2
IK6 Systemsure injector / spray....................................................................................................................... F.2
CombiMag power flushing filter......................................................................................................................F.6
CombiMag Split Twin power flushing filter......................................................................................................F.8
CombiMag Dual Digital power flushing filter and heater ................................................................................. F.9
Plate heat exchanger adapters...................................................................................................................... F.10
Radhammer radiator vibration tool............................................................................................................... F.11
Electronic test equipment –infra-red thermometer...................................................................................... F.12
Electronic test equipment –pH meter .......................................................................................................... F.13
Electronic test equipment –TDS meter......................................................................................................... F.14
Turbidity tube............................................................................................................................................... F.15
Water analysis test kit .................................................................................................................................. F.16
Additional water treatment chemicals .......................................................................................................... F.17
Section G –How to contact and locate Kamco Page
Helpline, e-mail, and website......................................................................................................................... G.1
Location map................................................................................................................................................. G.1
Section H –Warranty Page
Warranty....................................................................................................................................................... H.1

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section A –Introduction Page A.1
SECTION A –INTRODUCTION
TECHNICAL DATA
'CF40 Evolution' 'CF90 Quantum' 'CF210 Titan'
Pump Type: Vertical axis centrifugal Vertical axis centrifugal Vertical axis centrifugal
Motor nominal rating 0.5HP 0.75HP 0.75HP
kW (max.flow conditions): 0.80 kW 1.1 kW 1.1 kW
Degree of protection: IP55 IP55 IP55
Motor rating: Continuous Continuous Continuous
Temperature range: 0°C to 75°C 0°C to 75°C 0°C to 75°C
Dimensions (mm): W 390, D 440, H 690. W 390, D 590, H 890 W530, D670, H890
Hose connections: 3/4" BSP 3/4" BSP 1" BSP
Tank capacity (to filler cap) 39 litres 57 litres 125 litres
Weight (without hoses): 17kg 23kg 28kg
Wheels (dia): 75mm 200mm 200mm
# 230v models may be used on a domestic 13 ampere supply. A 5 ampere fuse should be fitted in the plug top.
A residual current circuit breaker adapter 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 EACH CLEARFLOW FLUSHING KIT
Each kit comprises the following:
Clearflow power flushing pump.
Set of 2 x 5m flow and return hoses.
1 x 8m dump hose.
1 x 3m overflow hose.
1 x 8m water inlet hose.
2 x circulation pump adapters.
10 part BSP adapter set (With CF40 & CF90 models only).
Waterproof container for hoses.
Comprehensive operating guidelines.
Starter pack of power flushing chemicals and corrosion inhibitor.
50 promotional leaflets for advertising.

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.1
SECTION B –USING THE CLEARFLOW PUMP FOR POWER FLUSHING
INTRODUCTION
Clearflow pumps are 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.
Pumps with 230 volt motors are single phase, for use on a
standard domestic supply. A 5 ampere fuse should be
fitted in the plug top. We recommend the use of a
residual current circuit breaker plug or adapter for extra
protection.
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
by another means.
6. Drain enough water from the system to empty the F&E
tank. This can be drained into the Clearflow tank if it
has already 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 flushing pump filling and overflowing the
expansion tank.
The F&E pipes may be capped with push fit end caps,
such as Speedfit, Prestek, or Hep2O, or a temporary
compression fitting gate valve.
Depending on the configuration of the heating
system looping the feed and expansion pipes
together may enable these pipes to be flushed during
the cleansing process, which can be beneficial when
the cold feed pipe contains corrosion deposits.
NOTE 1: This will only be effective when the F&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 Kamco hose, or Hep2O,
but should incorporate a valve in the loop to close the
circuit when flushing individual radiators.
Capping or looping together the F&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&E tank until after the
flushing pump has been connected into the system.
Tie up the f & e tank ballcock or otherwise turn off
the cold water feed, and return to the flushing 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 tank. Let the
water run until the tank is half full, and close both
isolating valves.
You should now have emptied the f & 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 & e tank it must be cleaned manually
and not drained into the system.

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.2
LOCATION AND CONNECTION OF THE CLEARFLOW POWER FLUSHING PUMP
The connection point for the flushing pump may vary
depending on the system to be cleaned, and the
availability of suitable connection points.
A recommended 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.2)
Ideally 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.
Hot water
storage
cylinder
Boiler
Alternative connection locations for a Clearflow pump
4
1
3
2
6
Use a CP2 circulator pump head adapter
fastened on to the pump body after
removal of the circulator pump motor.
Remove the complete circulator pump,
and connect onto the BSP threaded
pump fittings using adapter leads
supplied with the power flushing pump.
Connect across the flow and return pipe
work after removing the boiler.
Remove one radiator only, and connect
power flushing pump flow and return
hoses onto the valve bodies.
Break in to a length of copper pipe and
use push-fit connections.
1
2
3
4
5
Remove permanently installed domestic
size filter, and connect onto the valves or
fittings, using adapter if available.
6
Remove permanently installed
domestic size magnetic filter
5

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.3
1. Hose connections to the flushing pump
1a. Ensure that
both valves are
in the closed
position (i.e. the
valve handles
are horizontal).
1b. The pump
has two 5 metre
flow and return
hoses, fitted
with 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 rear
of the hose support plate. The other ends of these
hoses will be connected into the heating system.
1c. Connect the overflow hose connector to the BSP male
overflow fitting on the rear of the pump tank, and
lead to a suitable drain point.
1d. Connect the 8m dump hose to the brass nipple on the
reverse of the hose support plate, and lead the hose
to a toilet pan or drain pipe gully leading to a foul
sewer.
1e. Connect mains water supply hose BSP female hose
connector to the brass nipple on the rear of the hose
support plate. Fill the tank with water until above the
minimum liquid level, and then close the water inlet
valve.
1f. Plug in the pump to a suitable 13 ampere supply fitted
with an RCD adapter.
2. Hose connection to the system
Connect the flow and return hoses of the pump to the
system at the selected point. This may be either:
2a. Across the 1½" BSP
unions left once the
system 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.
A pair of 0. 5 m long adapter hoses, enabling the
pump to be connected across the 1½" unions, are
supplied as standard. When used, these are screwed
directly onto the female brass hose adapters of the
flow and return hoses, giving a total hose length of
5.5 m.
2b. Connection via the
optional CP2 pump
head adapter (see
page F.2). Remove the
socket head bolts that
attach the circulation
pump motor to the
pump body. Attach
the CP2 adapter to the
pump body and the
flow and return hoses
to the short lead hoses.
2c. Across the "tails" of a radiator (having drained and
disconnected the radiator) using appropriate 1/2" or
3/4" BSP adapters 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 adapter is not available.
2d. 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 the 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.

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.4
INITIAL FLUSHING PROCEDURE (WATER ONLY STAGE, BEFORE ADDITION OF CHEMICALS)
Note: In the following procedure, the pump is first
used to loosen and mobilise loose silt and debris,
before forcibly expelling it together with the existing
heavily contaminated system water. This rids the
system of as much debris and sludge at an early stage,
before establishing full, chemically treated circulation
through the flushing pump.
By removing loose corrosion products from the
system before addition of any chemical, the full effect
of the chemical is available to disturb, loosen, and
dissolve more stubborn accumulations of debris.
1. Leave the pump tank cap loose, or on by no more than
one turn if water splashes whilst flushing / descaling
(to allow gas to escape).
2. Check that both valves are closed (horizontal). Open
the isolating valves between flushing pump and
heating system and switch on pump immediately.
Ensure that liquid level in tank remains above the
minimum mark, adding more water if necessary.
3. Allow the flushing 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 for leaks.
5. The pump has the ability to dump dirty water with the
flow in either direction.
Change the pump 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.
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.
5b. Rotate the valve on the return side through 180° so
that the dump label is clearly visible.
By doing this, system water is diverted to waste down
the dump hose, instead of returning back into the
tank. The liquid level in the tank will immediately
begin to fall.
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 the
water level in the tank remains above the minimum
mark at all times.
Note: If the mains water cannot keep up with the
dump speed (i.e. the unit begins to empty) stop
dumping until the tank fills up.
Continued on next page.

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.5
6. Once the water remains reasonably clear, restore
circulation by rotating the valve back through 180°
into re-circulation mode.
7. Check that the liquid level in the tank remains 10cm
above the minimum mark. Add more water 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 discoloured and
likely to stain.
8. The flushing chemical may now be added. See page B.6
Leave the pump tank cap loose, or on by no more than
one turn, whilst flushing / descaling.

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.6
CHEMICAL FLUSHING PROCEDURE –WHICH CHEMICAL TO USE
Which chemical to use? POWERFLUSH FX2, or HYPERFLUSH.
Both of these chemicals will remove sludge, and POWERFLUSH FX2 will also remove scale from the heating system.
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 POWERFLUSH FX2?
Into the pump tank whilst power flushing, but not
beforehand.
Temperature required?
POWERFLUSH FX2 may be used cold (necessary when
changing a boiler), but works faster with temperature.
The very high flow rate of the pump means that during
power flushing it is not necessary to work at
temperatures above 60°C.
NEVER LEAVE POWERFLUSH FX2 IN A SYSTEM
HYPERFLUSH
Use HYPERFLUSH 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?
500ml per ten radiators (or 2 x 500ml if you consider the
system to be heavily sludged).
Where and when to add HYPERFLUSH?
Into the system 3-14 days prior to power flushing (via the
feed & expansion tank, or a SYSTEMSURE injector unit),
Directly into the pump tank whilst power flushing.
Temperature required?
HYPERFLUSH 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 pump means that
during power flushing it is not necessary to work at
temperatures above 60°C.
Use both HYPERFLUSH and POWERFLUSH FX2 if you consider the system to be heavily fouled.
Add HYPERFLUSH 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.
Use POWERFLUSH FX2 as usual on the day of the power flush, adding directly into the pump tank.

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.7
CHEMICAL FLUSHING PROCEDURE USING POWERFLUSH FX2
1. Switch on the Clearflow pump.
2. Whilst re-circulating water through the pump and
heating system, slowly add 2½ litres of POWERFLUSH
FX2 to the tank (sufficient for a 10-12 radiator
system), and ensure thorough distribution around the
system.
3. Switch on the boiler, if fitted, and in safe working
order. Allow the system water to reach 60°C, and then
switch boiler off.
NOTE: Even boiler thermostat setting no.1 could
exceed 50°C.
4. Circulate throughout the complete system for 15
minutes, reversing the flow direction regularly, and
monitoring the system for leaks.
5. Close off all radiators (one valve per radiator is
enough), and allow the full flow to go through the hot
water cylinder coil (if present in system).
6. Reverse the flow regularly.
7. Divert the full flow to the radiator circuit, in
preparation to putting the full flow of the pump
through each radiator in turn.
8. Fully open both valves of the nearest radiator on the
ground floor to the flushing pump.
9. Flush this radiator, reversing the flow regularly, until all
cold spots have disappeared, and the temperature
across the radiator is consistent. Close radiator valves.
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.
12. When you have flushed the last radiator, and
obtained an even temperature across the surface,
switch the pump into dumping mode, as previously.
13. With only this radiator open, and the pump set to
dump, run until the water leaving the dump hose is
completely clear. Operate the flow reverser and
change the valves to dump in the opposite direction
until clear. When water is clear, close radiator valve.
14. Go back to the previous radiator that you had flushed,
ensure both valves are open, and repeat the dumping
procedure on this one radiator, alternating the
direction of flow in each direction as you dump. Close
radiator valve.
15. Work your way back around the house in the
opposite direction to previously, until you have
carried out the dumping process on every radiator
individually.
16. Now with the pump still set to dump direct the flow
through the cylinder coil until it runs clear. Dump in
the other direction until clear.
Note: You have used an acidic cleaner, and therefore
a neutralising chemical should be circulated
throughout the system to ensure that no traces of
POWERFLUSH FX2 remain in the system. Whilst
POWERFLUSH FX2 contains specific inhibitors so that
its presence during a power flush presents no
problems, it is bad practice to leave system water
acidic over a long period of time.
17. Return the pump into normal re-circulation mode, re-
open all radiator valves, and the cylinder coil.
18. Slowly add 100 gm of
NEUTRALISING CRYSTALS
to the water in the pump
tank whilst circulating
throughout the system.
19. Circulate throughout the system for 10 to 15 minutes.
Continued on next page.

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.8
20. Switch the pump 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.13)
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 5-10% of each other.
23. Return to re-circulation mode and move to page B.10.

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.9
CHEMICAL FLUSHING PROCEDURE USING HYPERFLUSH
1. Switch on the Clearflow pump.
2. Whilst re-circulating water through the pump and the
heating system, slowly add 500ml of HYPERFLUSH to
the Clearflow tank, sufficient for 10-12 radiator
system, (unless it was added on a prior visit), and
ensure thorough distribution around the system.
3. Switch on the boiler, if fitted, and in safe working
order. Allow the system water to reach 50°C, and then
switch boiler off.
4. Circulate throughout the complete system for half to
one hour, reversing the flow direction regularly, and
monitoring the system for leaks.
5. Close off all radiators (one valve only), and allow the
full flow to go through the coil in the hot water
cylinder (if present in the system).
6. Reverse the flow regularly.
7. Divert the full flow to the radiator circuit, in
preparation to putting the full flow of the pump
through each radiator in turn.
8. Fully open both valves of the nearest radiator, on the
ground floor, to the flushing pump.
9. Flush this radiator, reversing the flow regularly, until all
cold spots have disappeared, and the temperature
across the radiator is consistent. Close the radiator
valves.
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.
12. When you have flushed the last radiator, and it has an
even temperature across the surface, switch the
pump into dumping mode, as previously.
13. With only this radiator open, and the pump set to
dump, run until the water leaving the dump hose is
completely clear. Now operate the flow reverser and
change the valves to dump in the opposite direction
until clear. When water is clear, close radiator valve.
14. Go back to the previous radiator that you had flushed,
ensure both valves are open, and repeat the dumping
procedure on this one radiator, alternating the
direction of flow in each direction as you dump. Close
radiator valve.
15. Work your way back around the house in the
opposite direction to previously, until you have
dumped on every radiator individually.
16. With the pump still set to dump direct the flow
through the cylinder coil until it runs clear. Dump in
the other direction until clear.
17. 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 5-10% of each other.
18. Return the flushing pump into normal re-circulation
mode, re-open all radiator valves, and the cylinder
coil, and move to page B.10.
19. NOTE: When using HYPERFLUSH there is no
requirement to neutralise after the flushing process.

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.10
INHIBITION AND CORROSION PROTECTION –SYSTEMSAFE-DM
IMPORTANT
1. The system is now full of fresh, clean water, and in line
with Building Regulations Part L: 2006, a good quality
corrosion inhibitor, such as SYSTEMSAFE-DM, must be
added to the system water to prevent further
corrosion and scaling.
To comply with Benchmark documentation, inhibitors
must have passed the NSF (formerly BUILDCERT)
product performance standard and can be identified
by this logo on the pack.
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 tank to just 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.
3. If the system is vented, the residual water in the
Clearflow tank, which will contain a small quantity of
inhibitor, may be poured into a bucket and added to
the F&E tank after this has been cleaned.
Note: In a pressurised system the inhibitor may be
injected into the system using an IK6 injector, which
will avoid wasting any inhibitor left in the tank (see
page F.4).
UPON COMPLETION
1. Restore system to normal, restoring radiator balance
valves to original settings, removing any temporary
isolating valves or caps on the expansion and cold
feed pipes, and restoring non return valves to normal
operation if necessary.
2. Before re-connecting the feed & expansion tank, it
should be thoroughly cleaned, removing all traces of
dirty water and sludge, and then disinfected with
Kamchlor chlorine release tablets.
NOTE: Clearflow pumps are also very powerful descaling
pumps, suitable for use when descaling the primary
water side of combination boiler heat exchangers, any
conventional domestic boiler, water heaters, direct fired
water heaters, thermal store type water heaters,
showers, and calorifiers.

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.11
QUICK GUIDE TO POWER FLUSHING PROCEDURE

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.12
SUMMARY OF CHEMICALS USED WHEN POWER FLUSHING
Product
Application
How much do you
need?
How is it packed?
POWERFLUSH
FX2
liquid
Power flushing.
For all systems except those
containing aluminium heat
exchangers or radiators.
Pour into the tank whilst re-
circulating.
2.5 litres
(half of a black 5l
pack) - up to 12
radiators.
Carton of 4 x 5 litre packs.
(sufficient for 8 power flushes).
Carton of 4 x 2.5 litre packs,
with 4 one-shot tubes of
Neutralising Crystals.
(sufficient for 4 power flushes).
Neutralising Crystals
To neutralise the system
water after dumping.
Pour slowly into the Clearflow
tank whilst re-circulating clean
water.
100 gm
per 2.5 litres of FX2.
Carton of 20 x 100gm tubes
Carton of 6 x 2.5 kg pails.
15kg pail.
pH paper
To check that acidity has
been removed.
Dip 3cm in dump water and
compare colour with chart.
Approx. 10 cm
used per flush.
5 metre dispenser pack.
(sufficient for at
least 50 power flushes).
HYPERFLUSH
Non-acid flushing
chemical
Power flushing systems
containing aluminium
or
to pre-treat heavily
sludged systems.
If possible, add to system 3 to
5 days before power flushing.
May be added on the day.
500ml (0.5 litre)
for up to 12 radiators.
Carton of 12 x 500ml packs.
(sufficient for 12 houses)
Carton of 4 x 2.5 litre packs
10 litre drum
SYSTEMSAFE-DM
corrosion & scale
inhibitor, for all heating
systems.
Protecting system.
Add to system via the pump
tank when power flushing is
complete, or via injector, or
into header tank.
500ml (0.5 litre)
for up to 12 radiators.
Carton of 12 x 500ml packs.
(sufficient for 12 houses)
Carton of 4 x 2.5 litre packs
10 litre drum

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.13
RADIATOR VALVE SETTINGS
Use a photo-copy of this chart to note the radiator valve settings before commencing to power flush the system, so
that the heating system can easily be re-instated afterwards, avoiding the need to rebalance the system.
Number of turns of valve to fully closed position:
Room
Radiator valve
Balance / lockshield valve
Hall
Cloakroom
Kitchen
Living room
Dining room
Downstairs hall
Upstairs hall
Bathroom
Bedroom 1
Bedroom 2
Bedroom 3
Bedroom 4
Bathroom 2
Other
Other

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.14
POWER FLUSHING SURVEY and CHECK LIST
Date: …………………………………………………………………………………………………………………….……
Address: ……………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………………
Name of householder / property owner: ………………………………Tel: ………………………………
Why does system need flushing?
Recommendation by other company
Previous survey
New boiler installation
British Gas / other?
Type of system:
Vented
Sealed
Fully pumped
Gravity hot water
Thermal store
(Need to cap off
cold feed and
expansion pipes.)
(Is there a non return valve on
return side of radiator circuit?)
Can gravity circuit be closed off?
Need valve to be fitted?
(Need to drain down and
loop out cylinder, and
flush radiator and boiler
circuits separately.)
Age of system:
Boiler
Radiators
Pipework
Type of boiler:
Conventional
Combi type
Condensing
Serial number:
If condensing boiler, is secondary
heat exchanger aluminium?
Location of boiler: ……………………………………………………………………………
Type of water cylinder:
None (combi system)
Conventional indirect
Primatic / Fortic
Thermal store
(Need to drain down and
loop out cylinder.)
(Need to drain down, loop out
cylinder, and flush radiator &
boiler circuits separately.)
Type of pipework:
Copper 15mm / 22mm
Microbore
Single pipe
Steel pipe work?
If microbore system, are twin entry radiator valves fitted? If so, are all radiators completely warm when boiler
fired? (i.e. are the radiator ‘injector’ tubes still fitted correctly?)

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.15
If single pipe system, is there circulation (heat) to all radiators? Cold radiators will need removal from system and
individual flushing.
If elderly steel pipe work, is system sufficiently sound to power flush? (Or would it be better to re-pipe?)
Location of system circulator pump:
In boiler casing
Adjacent to boiler
In airing cupboard
Elsewhere?
Best location to connect Clearflow pump?
On to circulator pump fittings
On to radiator
Elsewhere?
Number of radiators:
Steel
Aluminium
Are they all getting
warm?
TRVs fitted?
Any obvious signs of neglect / leaks?
Yes / No
Do all thermostatic radiator valves (TRVs) open fully?
Are there zone valves? Where are they located?
Number of valves
Airing cupboard
Elsewhere
Feed & expansion tank:
Location
Checked?
Condition?
Best place to connect onto for good fresh water supply? ……………………………………………………………………………………………...
Best place to locate power flushing pump? ……………………………………………………………………………………………………………………
Across circulator pump
fittings
Across radiator tails
Across flow and return at
boiler
Across flow and return pipe
work from disconnected
cylinder
Need to use a drip tray? …………………………………………………….
Best place to run dump hose to? ……………………………………………………………….
Toilet
Outside drain
Elsewhere?
Colour of heating system water, as run from bottom of a radiator:
Clear
Orange
Dark brown
Black

CLEARFLOW CF40, CF90 and CF210
OPERATING and SERVICING GUIDELINES
Issue: May 2023 Section B –Using the Clearflow pump Page B.16
POWER FLUSH MONITORING FORM
Visual inspection of system water before power flush:
Clear
Orange
Dark brown
Black
Analysis results
Test parameter
Mains water
System water before
power flush
System water after
power flush
pH
Soluble iron (ppm)
Soluble copper (ppm)
Chloride (ppm)
Hardness
Inhibitor (ppm molybdate)
TDS (Total Dissolved Solids) readings
Mains water (ppm)
System water before flush (ppm)
When checking dump water TDS from each radiator when dumping, note results below (ppm):
Radiator 1
Radiator 8
Radiator 15
Radiator 2
Radiator 9
Radiator 15
Radiator 3
Radiator 10
Radiator 17
Radiator 4
Radiator 11
Radiator 18
Radiator 5
Radiator 12
Radiator 19
Radiator 6
Radiator 13
Radiator 20
Radiator 7
Radiator 14
Radiator 21
Flushing chemical used:
POWERFLUSH FX2
HYPERFLUSH
Corrosion inhibitor used:
SYSTEMSAFE-DM
The undersigned has power flushed the system according to best industry practice and following procedures
detailed in code of practice BS7593
Name:
Signature:
Date: