ROTHENBERGER ROCAL PRO 2 Power Flusher Instruction Manual

: June 4, 2024
: Rothenberger

Table of Contents

ROTHENBERGER ROCAL PRO 2 Power Flusher
SAFETY INSTRUCTIONS
INTRODUCTION
REGULATIONS – CE MARK
DESCRIPTION
TECHNICAL FEATURES
USE
- POWER FLUSHING
- DESCALING
CHEMICALS
- CONDITIONING CHEMICALS Suitable for all materials
DIRECTIONS FOR DISPOSAL
CUSTOMER SERVICES
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

ROTHENBERGER ROCAL PRO 2 Power Flusher

PRECAUTIONS

Only use Rothenberger chemicals in order to ensure good performance and avoid damaging the equipments.
Once the lifetime of the pump has expired, do not dispose of it with household waste. The pump must be recycled in authorized centres and can be treated as a household appliance.
During handling lift the pump and do not drag it to avoid damage to the tank.
Temperature of the descaling solution must never exceed 50 °C.
Flexible hoses and fittings can damage in time, check the seals whenever using the pump, as indicated in the pump preparation instructions.

SAFETY INSTRUCTIONS

Avoid using the pump in places where there are liquids, gases, flammable powders or with risk of explosion.
Before plugging in the pump, make sure the main switch on the machine is off.
Only use CE-marked outlets.
Use (CE) approved extensions, only if necessary.
Do not use plug adapters. Do not carry out any modifications to the plug nor to the electrical cable.
Pump shall always be kept in perfect efficiency.
During maintenance operations, check the switch is off and the plug is not connected.
Maintenance operations must be carried out by the authorized Rothenberger Technician..
Only use Rothenberger original spare parts.
Do not carry out any modifications to the pump if not authorized by Rothenberger Technical Department (ask for written authorization).
Keep children and unauthorized persons away from the pump.
Keep the pump out of reach of children and unauthorized persons.
Do not use the pump if tired or under the effect of alcohol, medicines or drugs.
When using the pump, wear overalls, do not wear jewellery, keep hair away from the pump.
When handling chemicals, take care.
Always use Personal Protection Equipment (PPE).
Equipment can be used by children under 8 years and by people with reduced physical, mental, sensorial capacity, or by people without experience or the necessary know-how, provided they are supervised or have received received adequate training, which should include the correct use of the equipment and the risks that may arise from its use.
Please ensure that children do not play with the appliance.
Cleaning and maintenance are intended to be performed by the user and must not be carried out by children without supervision.
If power cord is damaged, it must be replaced by the manufacturer or by Rothenberger Service Technician or a similarly qualified person, in order to avoid any hazard.”

INTRODUCTION

With time and, above all, temperature increase, magnesium and calcium salts contained in water form microcrystals and settle on metallic surfaces of pipes, plant coils and heat exchangers, thus reducing flow rate and thermal efficiency.
To remove scale deposits it is necessary to flush the inside the pipes, by using a Rothenberger descaling pumps, the chemicals which react with scale, make it soluble and thus removed. Rothenberger produces a wide range of products for descaling systems and heat exchangers etc.
All products are made from high quality base materials in order to get

REGULATIONS – CE MARK

Declaration of Conformity
The pumps are in conformity with the following European Directives, Laws and Regulations:
Low Voltage Directive:
73/23/EEC
93/68/EEC
Electromagnetic Compatibility Directive:
89/336/EEC
92/31/EEC
93/68/EEC
93/97/EEC
Directives RoHS and WEEE:
02/98/EEC
02/96/EEC
03/108/EEC
QUALITY
The pump is built with high-quality acid resistant materials and submitted to severe operating tests.
Follow these instructions to avoid any operating and servicing problems.

DESCRIPTION

Vertical axis pump with tank and on-off valves for cleaning and flushing small systems or parts of big systems by circulating specific non-acid flushing chemicals and/or acid descaling solutions.
Exclusive pump design with tank. Highly portable format, with handle and wheels for easy transportation.
Thanks to the automatic flow reverser function (Rothenberger patent), it attacks scale in both directions, thus making descaling more effective and fast (as the chemical dissolving action is combined with the removal of flakes of scale, which is aided by the two way flow), even when pipes and exchangers are almost totally blocked.
Deposits which can be removed with the pump ROCAL PRO 2:
- scale deposits.
- calcium and silica deposits.
- iron and/or manganese oxides.
- iron bacteria and/or sulfate-reducing bacteria .
- organic substances and/or mucilage’s and algae.

TECHNICAL FEATURES

Vertical axis pump

Motor: Hp 0,75
Power supply: 230 V – 50 Hz
Degree of protection: IP 54
Max. temperature: 50° C
Flow rate: 102 l/min.
Head: 18 m
Connections: 1” F
Tank capacity: 40 l
Dimensions (LxHxD): 40 x 95 x 70 cm
Weight: 19 Kg

BOILER FLUSHING
Please consult boiler manufacturer prior to flushing, regarding warranties and suitability of use.

USE

DESCALING WITH FLOW REVERSER
For descaling boilers and heat exchangers.
Fill the tank with the correct volume of descaling chemical according to the size and type of system, and enough water to ensure that the liquid level is between the minimum “MIN” and maximum “MAX” level.
TEMPERATURE OF THE DESCALING SOLUTION MUST NEVER EXCEED 50 °C.

Connect the outer ends of the flexible reinforced hoses to the equipment to be descaled.
Connect the power cable to a single-phase 230 V – 50 Hz power supply.
During operation, the tank cap should remain open to allow for the venting of the fumes produced during descaling. Check that the
foam level does not exceed the maximum filling level.
Set the 2 three-way valves as shown in the figure below, close the clean water inlet tap and switch on the pump.
Rotate the flow reverser lever right and left regularly to aid descaling and make flushing more effective.
When water colour starts changing, immediately refill, as the solution is exhausted.
Scale removal can be considered complete when bubbles no longer form in the return pipe and the solution is still acidic.
After descaling flush the system with the product NEUTRALIZING for removing residual acidity, once the pump has been emptied of the product.

Important: Do not leave the descaling solution inside the tank for any reason.

POWER FLUSHING

Pre-flushing with water
Pump is suitable for power flushing and descaling boilers*, heat exchangers as well as radiator, underfloor and solar heating systems. To carry out the pre- flushing with water (and then the power flushing), operate as follows:

Connect the ends of the flexible hoses to the system to be flushed.
Connect the overflow hose to a suitable drain.
Connect the power supply cable to a single-phase 230 V / 50 Hz socket.
Open the tank cap to visually check water level in the tank.
Set the valves and flow reverser , open the clean water inlet tap, open the dump and switch on the pump.
Notice: The direction of the longer part of the valve knob
Circulate water in the system for approximately 2 minutes to remove the rough deposits present in the pipes.
Set the valves and reverse the flow.
Switch on the pump and circulate water in the system for approximately 2 minutes to remove the rough deposits present in the pipes.
Repeat the pre-flushing to right and left until dump water is free from rough deposits.

Power flushing with chemical (ROCLEAN RESTORER)
To power flush the system with the chemical (Long Life 800), operate as follows:

Make sure the ends of the flexible hoses are connected to the system to be power flushed.
Make sure that the overflow hose is connected to a suitable drain.
Make sure that the power supply cable is connected to a single-phase 230 V / 50 Hz socket.
Close the mains water inlet supply tap and close the dump.
Make sure that the tank cap is open to visually check fluid level in the tank.
Set the valves and add the chemical into the tank.
Circulate the chemical solution in the system circuit for approximately 5- 10 minutes.
After 5-10 minutes reverse the flow.
Circulate the chemical in the system circuit for approximately 5-10 minutes.
Repeat the power flushing operations switching the flow to right and left, until the colour of the flushing solution changes, for a minimum working time of 2-3 hours.

Rinsing with water
To rinse with water after power flushing, operate as follows:

Make sure that the overflow hose is connected to a suitable drain.
Make sure that the power supply cable is connected to a single-phase 230 V / 50 Hz socket.
Make sure that the tank cap is open to visually check water level in the tank.
Open the dump.
Set the valves , open the clean water inlet tap and switch on the pump.
Circulate water in the system for some minutes to remove the flushing residues present in the pipes.
Set the valves and reverse the flow.
Switch on the pump and circulate water in the system for a few minutes to remove the flushing residues present in the pipes.
Measure conductivity of the mains water at the inlet and dump water at the outlet.
Repeat the rinsing operations until the dump water runs clear.

Chemical filling (ROCLEAN INHIBITOR)

Close mains water supply tap.
Close dump
Set the valves .
Add chemical (corrosion inhibitor and/or biocide-sanitizer) into the tank.
Switch on the pump for a few minutes.

DESCALING

Descaling with chemicals
To carry out descaling with chemicals, operate as follows:

Connect the ends of the flexible hoses to the system to be descaled.
Connect the overflow hose to a suitable drain.
Connect the power supply cable to a single-phase 230 V / 50 Hz socket.
Make sure the tank cap is open, to allow any fumes formed during descaling to escape.
Set the valves , add the chemical into the tank.
Circulate the chemical in the system circuit for approximately 5-10 minutes.
Once this time has passed, reverse the flow leaving the position of valves as they are.
Should the chemical be changing its initial colour, it should be refilled immediately as exhausted.
Repeat the operations until the colour of the flushing solution is changes, for a minimum working time of 2-3 hours.
After descaling, open the dump to evacuate residual acid caused by descaling and go to the next step (Neutralization after descaling).
Notice: Use descaling chemicals suitable for the system materials.

Neutralization
To neutralize the system with NEUTRALIZING, operate as follows:

Make sure the tank cap is open to visually check water level in the tank.
Pour a 2-3% amount of NEUTRALIZING by referring to the warnings on the packaging and product label.
Set the valves and flow reverser as per Figure 5. Open the clean water inlet tap and switch on the pump.
Circulate the neutralizing solution in the system for approximately 2 minutes to neutralize residual acidity present in the equipment.
Once this time has passed, set the valves and flow reverser
Circulate the neutralizing solution in the system for approximately 2 minutes to remove residual acidity present in the equipment.
Repeat the operations until dump water is free from any chemical residues.
Dump the neutralizing solution used.

CHEMICALS

CONDITIONING CHEMICALS Suitable for all materials

ROCLEAN INHIBITOR
Corrosion inhibitor. Non acid product to control corrosion and scale in boilers and heating systems.
ROCLEAN RESTORER
Restorer. Flushing product to remove sludge, corrosion residues and iron deposits built over time in heating systems. Suitable for traditional heating systems.

DIRECTIONS FOR DISPOSAL

Components of the unit are made from recyclable material and should be put to recycled. For this purpose registered and certified recycling companies are available. For an environmental friendly disposal of the non-recyclable parts (e.g. electronic waste) please contact your local waste disposal authority.
For EU countries only:
Do not dispose electric tools with domestic waste. In accordance with the European Directive 2012/19/EC the disposal of electrical and electronic equipment and its implementation as national law, electric tools that are no longer serviceable must be collected separately and utilized for environmentally compatible recycling.

CUSTOMER SERVICES

The ROTHENBERGER service locations are available to help you (see listing in catalog or on- line) and replacement parts and service are also available through these same service locations.
Order your accessories and spare parts from your specialist retailer or using our service-after- sales hotline:
Phone: 01536 310300
Fax: 01536 310600
Email: sales@rothenberger.co.uk
www.rothenberger.co.uk

DECLARATION OF CONFORMITY
We declare on our sole accountability that this product conforms to the standards and guidelines stated.